Abrasive article including shaped abrasive particles

ABSTRACT

A fixed abrasive article including a blend of abrasive particles having a first type of shaped abrasive particle comprising a first height (h1), a second type of shaped abrasive particle comprising a second height (h2) less than the first height, where the blend of abrasive particles includes a first content of the first type of shaped abrasive particles and a second content of the second type of shaped abrasive particle, and the first content is different as compared to the second content.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation of and claims priority under 35U.S.C. § 120 to U.S. patent application Ser. No. 15/402,786, entitled“Abrasive Article Including Shaped Abrasive Particles,” by SujathaIyengar, filed Jan. 10, 2017, which is a continuation of and claimspriority under 35 U.S.C. § 120 to U.S. patent application Ser. No.14/579,143, entitled “Abrasive Article Including Shaped AbrasiveParticles,” by Sujatha Iyengar, filed Dec. 22, 2014, now U.S. Pat. No.9,566,689, which claims priority under 35 U.S.C. § 119(e) to U.S. PatentApplication No. 61/922,206 entitled “Abrasive Article Including ShapedAbrasive Particles,” by Sujatha Iyengar, filed Dec. 31, 2013, all ofwhich are assigned to the current assignee hereof and incorporatedherein by reference in their entireties.

BACKGROUND Field of the Disclosure

The following is directed to abrasive articles, and particularly,abrasive articles including shaped abrasive particles.

Description of the Related Art

Abrasive particles and abrasive articles made from abrasive particlesare useful for various material removal operations, including grinding,finishing, and polishing. Depending upon the type of abrasive material,such abrasive particles can be useful in shaping or grinding a widevariety of materials and surfaces in the manufacturing of goods. Certaintypes of abrasive particles have been formulated to date that haveparticular geometries, such as triangular shaped abrasive particles andabrasive articles incorporating such objects. See, for example, U.S.Pat. Nos. 5,201,916; 5,366,523; and 5,984,988.

Three basic technologies that have been employed to produce abrasiveparticles having a specified shape are (1) fusion, (2) sintering, and(3) chemical ceramic. In the fusion process, abrasive particles can beshaped by a chill roll, the face of which may or may not be engraved, amold into which molten material is poured, or a heat sink materialimmersed in an aluminum oxide melt. See, for example, U.S. Pat. No.3,377,660 (disclosing a process including flowing molten abrasivematerial from a furnace onto a cool rotating casting cylinder, rapidlysolidifying the material to form a thin semisolid curved sheet,densifying the semisolid material with a pressure roll, and thenpartially fracturing the strip of semisolid material by reversing itscurvature by pulling it away from the cylinder with a rapidly drivencooled conveyor).

In the sintering process, abrasive particles can be formed fromrefractory powders having a particle size of up to 10 micrometers indiameter. Binders can be added to the powders along with a lubricant anda suitable solvent, e.g., water. The resulting mixture, mixtures, orslurries can be shaped into platelets or rods of various lengths anddiameters. See, for example, U.S. Pat. No. 3,079,242 (disclosing amethod of making abrasive particles from calcined bauxite materialincluding (1) reducing the material to a fine powder, (2) compactingunder affirmative pressure and forming the fine particles of said powderinto grain-sized agglomerations, and (3) sintering the agglomerations ofparticles at a temperature below the fusion temperature of the bauxiteto induce limited recrystallization of the particles, whereby abrasivegrains are produced directly to size).

Chemical ceramic technology involves converting a colloidal dispersionor hydrosol (sometimes called a sol), optionally in a mixture, withsolutions of other metal oxide precursors, into a gel or any otherphysical state that restrains the mobility of the components, drying,and firing to obtain a ceramic material. See, for example, U.S. Pat.Nos. 4,744,802 and 4,848,041.

Still, there remains a need in the industry for improving performance,life, and efficacy of abrasive particles, and the abrasive articles thatemploy abrasive particles.

SUMMARY

A fixed abrasive article including a blend of abrasive particles havinga first type of shaped abrasive particle comprising a first height (h1),a second type of shaped abrasive particle comprising a second height(h2) less than the first height.

A fixed abrasive article comprising a blend of abrasive particlescomprising a first type of shaped abrasive particle comprising a firstheight (h1), a second type of shaped abrasive particle comprising asecond height (h2) less than the first height, and wherein the fixedabrasive article comprises a stainless steel lifespan of at least about11 in³.

A method of removing material from a workpiece using an abrasive articleincluding a blend of abrasive particles comprising a first type ofshaped abrasive particle comprising a first height (h1), and a secondtype of shaped abrasive particle comprising a second height (h2) lessthan the first height.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be better understood, and its numerousfeatures and advantages made apparent to those skilled in the art byreferencing the accompanying drawings.

FIG. 1A includes a portion of a system for forming a particulatematerial in accordance with an embodiment.

FIG. 1B includes a portion of the system of FIG. 1A for forming aparticulate material in accordance with an embodiment.

FIG. 2 includes a portion of a system for forming a particulate materialin accordance with an embodiment.

FIG. 3A includes a perspective view illustration of a shaped abrasiveparticle according to an embodiment.

FIG. 3B includes a cross-sectional illustration of the shaped abrasiveparticle of FIG. 3A.

FIG. 4 includes a side view of a shaped abrasive particle and percentageflashing according to an embodiment.

FIG. 5 includes a cross-sectional illustration of a portion of a coatedabrasive article according to an embodiment.

FIG. 6 includes a cross-sectional illustration of a portion of a coatedabrasive article according to an embodiment.

FIG. 7 includes a top-down illustration of a portion of a coatedabrasive article according to an embodiment.

FIG. 8A includes a top-down illustration of a portion of a coatedabrasive article according to an embodiment.

FIG. 8B includes a perspective view illustration of a portion of acoated abrasive article according to an embodiment.

FIG. 9 includes a perspective view illustration of a portion of a coatedabrasive article according to an embodiment.

FIG. 10 includes a top view illustration of a portion of an abrasivearticle in accordance with an embodiment.

FIG. 11 includes a plot of specific grinding energy versus cumulativematerial removed for a sample corresponding to an embodiment herein andtwo conventional samples.

FIG. 12 includes images representative of portions of a coated abrasiveaccording to an embodiment and used to analyze the orientation of shapedabrasive particles on the backing.

DETAILED DESCRIPTION

The following is directed to abrasive articles including. The methodsherein may be utilized in forming shaped abrasive particles and usingabrasive articles incorporating shaped abrasive particles. The shapedabrasive particles may be utilized in various applications, includingfor example coated abrasives, bonded abrasives, free abrasives, and acombination thereof. Various other uses may be derived for the shapedabrasive particles.

Shaped Abrasive Particles

Various methods may be utilized to obtain shaped abrasive particles. Theparticles may be obtained from a commercial source or fabricated. Somesuitable processes used to fabricate the shaped abrasive particles caninclude, but are not limited to, screen-printing, molding, pressing,casting, sectioning, cutting, dicing, punching, drying, curing,depositing, coating, extruding, rolling, and a combination thereof.

FIG. 1A includes an illustration of a system 150 for forming a shapedabrasive particle in accordance with one non-limiting embodiment. Theprocess of forming shaped abrasive particles can be initiated by forminga mixture 101, including a ceramic material and a liquid. In particular,the mixture 101 can be a gel formed of a ceramic powder material and aliquid, wherein the gel can be characterized as a shape-stable materialhaving the ability to substantially hold a given shape even in the green(i.e., unfired) state. In accordance with an embodiment, the gel can beformed of the ceramic powder material as an integrated network ofdiscrete particles.

The mixture 101 may contain a certain content of solid material, liquidmaterial, and additives such that it has suitable rheologicalcharacteristics for use with the process detailed herein. That is, incertain instances, the mixture can have a certain viscosity, and moreparticularly, suitable rheological characteristics that form adimensionally stable phase of material that can be formed through theprocess as noted herein. A dimensionally stable phase of material is amaterial that can be formed to have a particular shape and substantiallymaintain the shape for at least a portion of the processing subsequentto forming. In certain instances, the shape may be retained throughoutsubsequent processing, such that the shape initially provided in theforming process is present in the finally-formed object.

The mixture 101 can be formed to have a particular content of solidmaterial, such as the ceramic powder material. For example, in oneembodiment, the mixture 101 can have a solids content of at least about25 wt %, such as at least about 35 wt %, or even at least about 38 wt %for the total weight of the mixture 101. Still, in at least onenon-limiting embodiment, the solids content of the mixture 101 can benot greater than about 75 wt %, such as not greater than about 70 wt %,not greater than about 65 wt %, not greater than about 55 wt %, notgreater than about 45 wt %, or not greater than about 42 wt %. It willbe appreciated that the content of the solids materials in the mixture101 can be within a range between any of the minimum and maximumpercentages noted above.

According to one embodiment, the ceramic powder material can include anoxide, a nitride, a carbide, a boride, an oxycarbide, an oxynitride, anda combination thereof. In particular instances, the ceramic material caninclude alumina. More specifically, the ceramic material may include aboehmite material, which may be a precursor of alpha alumina. The term“boehmite” is generally used herein to denote alumina hydrates,including mineral boehmite, typically being Al₂O₃.H₂O and having a watercontent on the order of 15%, as well as pseudoboehmite, having a watercontent higher than 15%, such as 20-38% by weight. It is noted thatboehmite (including pseudoboehmite) has a particular and identifiablecrystal structure, and therefore a unique X-ray diffraction pattern. Assuch, boehmite is distinguished from other aluminous materials,including other hydrated aluminas such as ATH (aluminum trihydroxide), acommon precursor material used herein for the fabrication of boehmiteparticulate materials.

Furthermore, the mixture 101 can be formed to have a particular contentof liquid material. Some suitable liquids may include water. Inaccordance with one embodiment, the mixture 101 can be formed to have aliquid content less than the solids content of the mixture 101. In moreparticular instances, the mixture 101 can have a liquid content of atleast about 25 wt % for the total weight of the mixture 101. In otherinstances, the amount of liquid within the mixture 101 can be greater,such as at least about 35 wt %, at least about 45 wt %, at least about50 wt %, or even at least about 58 wt %. Still, in at least onenon-limiting embodiment, the liquid content of the mixture can be notgreater than about 75 wt %, such as not greater than about 70 wt %, notgreater than about 65 wt %, not greater than about 62 wt %, or even notgreater than about 60 wt %. It will be appreciated that the content ofthe liquid in the mixture 101 can be within a range between any of theminimum and maximum percentages noted above.

Furthermore, to facilitate processing and forming shaped abrasiveparticles according to embodiments herein, the mixture 101 can have aparticular storage modulus. For example, the mixture 101 can have astorage modulus of at least about 1×10⁴ Pa, such as at least about 4×10⁴Pa, or even at least about 5×10⁴ Pa. However, in at least onenon-limiting embodiment, the mixture 101 may have a storage modulus ofnot greater than about 1×10⁷ Pa, such as not greater than about 2×10⁶Pa. It will be appreciated that the storage modulus of the mixture 101can be within a range between any of the minimum and maximum valuesnoted above.

The storage modulus can be measured via a parallel plate system usingARES or AR-G2 rotational rheometers, with Peltier plate temperaturecontrol systems. For testing, the mixture 101 can be extruded within agap between two plates that are set to be approximately 8 mm apart fromeach other. After extruding the gel into the gap, the distance betweenthe two plates defining the gap is reduced to 2 mm until the mixture 101completely fills the gap between the plates. After wiping away excessmixture, the gap is decreased by 0.1 mm, and the test is initiated. Thetest is an oscillation strain sweep test conducted with instrumentsettings of a strain range between 0.01% to 100%, at 6.28 rad/s (1 Hz),using 25-mm parallel plate and recording 10 points per decade. Within 1hour after the test completes, the gap is lowered again by 0.1 mm, andthe test is repeated. The test can be repeated at least 6 times. Thefirst test may differ from the second and third tests. Only the resultsfrom the second and third tests for each specimen should be reported.

Furthermore, to facilitate processing and forming shaped abrasiveparticles according to embodiments herein, the mixture 101 can have aparticular viscosity. For example, the mixture 101 can have a viscosityof at least about 4×10³ Pa s, at least about 5×10³ Pa s, at least about6×10³ Pa s, at least about 8×10³ Pa s, at least about 10×10³ Pa s, atleast about 20×10³ Pa s, at least about 30×10³ Pa s, at least about40×10³ Pa s, at least about 50×10³ Pa s, at least about 60×10³ Pa s, orat least about 65×10³ Pa s. In at least one non-limiting embodiment, themixture 101 may have a viscosity of not greater than about 100×10³ Pa s,such as not greater than about 95×10³ Pa s, not greater than about90×10³ Pa s, or even not greater than about 85×10³ Pa s. It will beappreciated that the viscosity of the mixture 101 can be within a rangebetween any of the minimum and maximum values noted above. The viscositycan be measured in the same manner as the storage modulus as describedabove.

Moreover, the mixture 101 can be formed to have a particular content oforganic materials, including, for example, organic additives that can bedistinct from the liquid to facilitate processing and formation ofshaped abrasive particles according to the embodiments herein. Somesuitable organic additives can include stabilizers, binders such asfructose, sucrose, lactose, glucose, UV curable resins, and the like.

Notably, the embodiments herein may utilize a mixture 101 that can bedistinct from slurries used in conventional forming operations. Forexample, the content of organic materials within the mixture 101 and, inparticular, any of the organic additives noted above may be a minoramount as compared to other components within the mixture 101. In atleast one embodiment, the mixture 101 can be formed to have not greaterthan about 30 wt % organic material for the total weight of the mixture101. In other instances, the amount of organic materials may be less,such as not greater than about 15 wt %, not greater than about 10 wt %,or even not greater than about 5 wt %. Still, in at least onenon-limiting embodiment, the amount of organic materials within themixture 101 can be at least about 0.01 wt %, such as at least about 0.5wt % for the total weight of the mixture 101. It will be appreciatedthat the amount of organic materials in the mixture 101 can be within arange between any of the minimum and maximum values noted above.

Moreover, the mixture 101 can be formed to have a particular content ofacid or base, distinct from the liquid content, to facilitate theprocessing and formation of shaped abrasive particles according to theembodiments herein. Some suitable acids or bases can include nitricacid, sulfuric acid, citric acid, chloric acid, tartaric acid,phosphoric acid, ammonium nitrate, and ammonium citrate. According toone particular embodiment in which a nitric acid additive is used, themixture 101 can have a pH of less than about 5, and more particularly,can have a pH within a range between about 2 and about 4.

The system 150 of FIG. 1A, can include a die 103. As illustrated, themixture 101 can be provided within the interior of the die 103 andconfigured to be extruded through a die opening 105 positioned at oneend of the die 103. As further illustrated, extruding can includeapplying a force 180 (such as a pressure) on the mixture 101 tofacilitate extruding the mixture 101 through the die opening 105. In anembodiment, the system 150 can generally be referred to as a screenprinting process. During extrusion within an application zone 183, ascreen 151 can be in direct contact with a portion of a belt 109. Thescreen printing process can include extruding the mixture 101 from thedie 103 through the die opening 105 in a direction 191. In particular,the screen printing process may utilize the screen 151 such that, uponextruding the mixture 101 through the die opening 105, the mixture 101can be forced into an opening 152 in the screen 151.

In accordance with an embodiment, a particular pressure may be utilizedduring extrusion. For example, the pressure can be at least about 10kPa, such as at least about 500 kPa. Still, in at least one non-limitingembodiment, the pressure utilized during extrusion can be not greaterthan about 4 MPa. It will be appreciated that the pressure used toextrude the mixture 101 can be within a range between any of the minimumand maximum values noted above. In particular instances, the consistencyof the pressure delivered by a piston 199 may facilitate improvedprocessing and formation of shaped abrasive particles. Notably,controlled delivery of consistent pressure across the mixture 101 andacross the width of the die 103 can facilitate improved processingcontrol and improved dimensional characteristics of the shaped abrasiveparticles.

Referring briefly to FIG. 1B, a portion of the screen 151 isillustrated. As shown, the screen 151 can include the opening 152, andmore particularly, a plurality of openings 152 extending through thevolume of the screen 151. In accordance with an embodiment, the openings152 can have a two-dimensional shape as viewed in a plane defined by thelength (l) and width (w) of the screen. The two-dimensional shape caninclude various shapes such as, for example, polygons, ellipsoids,numerals, Greek alphabet letters, Latin alphabet letters, Russianalphabet characters, complex shapes including a combination of polygonalshapes, and a combination thereof. In particular instances, the openings152 may have two-dimensional polygonal shapes such as a triangle, arectangle, a quadrilateral, a pentagon, a hexagon, a heptagon, anoctagon, a nonagon, a decagon, and a combination thereof.

As further illustrated, the screen 151 can have openings 152 that areoriented in a particular manner relative to each other. As illustratedand in accordance with one embodiment, each of the openings 152 can havesubstantially the same orientation relative to each other andsubstantially the same orientation relative to the surface of thescreen. For example, each of the openings 152 can have a first edge 154defining a first plane 155 for a first row 156 of the openings 152extending laterally across a lateral axis 158 of the screen 151. Thefirst plane 155 can extend in a direction substantially orthogonal to alongitudinal axis 157 of the screen 151. However, it will be appreciatedthat in other instances, the openings 152 need not necessarily have thesame orientation relative to each other.

Moreover, the first row 156 of openings 152 can be oriented relative toa direction of translation to facilitate particular processing andcontrolled formation of shaped abrasive particles. For example, theopenings 152 can be arranged on the screen 151 such that the first plane155 of the first row 156 defines an angle relative to the direction oftranslation 171. As illustrated, the first plane 155 can define an anglethat is substantially orthogonal to the direction of translation 171.Still, it will be appreciated that in one embodiment, the openings 152can be arranged on the screen 151 such that the first plane 155 of thefirst row 156 defines a different angle with respect to the direction oftranslation, including, for example, an acute angle or an obtuse angle.Still, it will be appreciated that the openings 152 may not necessarilybe arranged in rows. The openings 152 may be arranged in variousparticular ordered distributions with respect to each other on thescreen 151, such as in the form of a two-dimensional pattern.Alternatively, the openings may be disposed in a random manner on thescreen 151.

Referring again to FIG. 1A, after forcing the mixture 101 through thedie opening 105 and a portion of the mixture 101 through the openings152 in the screen 151, one or more precursor shaped abrasive particles123 may be printed on the belt 109 disposed under the screen 151.According to a particular embodiment, the precursor-shaped abrasiveparticles 123 can have a shape substantially replicating the shape ofthe openings 152. Notably, the mixture 101 can be forced through thescreen in rapid fashion, such that the average residence time of themixture 101 within the openings 152 can be less than about 2 minutes,less than about 1 minute, less than about 40 seconds, or even less thanabout 20 seconds. In particular non-limiting embodiments, the mixture101 may be substantially unaltered during printing as it travels throughthe screen openings 152, thus experiencing no change in the amount ofcomponents from the original mixture, and may experience no appreciabledrying in the openings 152 of the screen 151.

Additionally, the system 151 can include a bottom stage 198 within theapplication zone 183. During the process of forming shaped abrasiveparticles, the belt 109 can travel over the bottom stage 198, which canoffer a suitable substrate for forming. According to one embodiment, thebottom stage 198 can include a particularly rigid constructionincluding, for example, an inorganic material such as a metal or metalalloy having a construction suited to facilitating the formation ofshaped abrasive particles according to embodiments herein. Moreover, thebottom stage 198 can have an upper surface that is in direct contactwith the belt 109, and that has a particular geometry and/or dimension(e.g., flatness, surface roughness, etc.), which can also facilitateimproved control of dimensional characteristics of the shaped abrasiveparticles.

During operation of the system 150, the screen 151 can be translated ina direction 153 while the belt 109 can be translated in a direction 110substantially similar to the direction 153, at least within theapplication zone 183, to facilitate a continuous printing operation. Assuch, the precursor-shaped abrasive particles 123 may be printed ontothe belt 109 and translated along the belt 109 to undergo furtherprocessing. It will be appreciated that such further processing caninclude processes described in the embodiments herein, including forexample, shaping, application of other materials (e.g., dopantmaterial), drying, and the like.

In some embodiments, the belt 109 and/or the screen 151 can betranslated while extruding the mixture 101 through the die opening 105.As illustrated in the system 100, the mixture 101 may be extruded in adirection 191. The direction of translation 110 of the belt 109 and/orthe screen 151 can be angled relative to the direction of extrusion 191of the mixture 101. While the angle between the direction of translation110 and the direction of extrusion 191 is illustrated as substantiallyorthogonal in the system 100, other angles are contemplated, includingfor example, an acute angle or an obtuse angle.

The belt 109 and/or the screen 151 may be translated at a particularrate to facilitate processing. For example, the belt 109 and/or thescreen 151 may be translated at a rate of at least about 3 cm/s. Inother embodiments, the rate of translation of the belt 109 and/or thescreen 151 may be greater, such as at least about 4 cm/s, at least about6 cm/s, at least about 8 cm/s, or even at least about 10 cm/s. Still, inat least one non-limiting embodiment, the belt 109 and/or the screen 151may be translated in a direction 110 at a rate of not greater than about5 m/s, not greater than about 1 m/s, or even not greater than about 0.5m/s. It will be appreciated that the belt 109 and/or the screen 151 maybe translated at a rate within a range between any of the minimum andmaximum values noted above, and moreover, may be translated atsubstantially the same rate relative to each other. Furthermore, forcertain processes according to embodiments herein, the rate oftranslation of the belt 109 as compared to the rate of extrusion of themixture 101 in the direction 191 may be controlled to facilitate properprocessing.

After the mixture 101 is extruded through the die opening 105, themixture 101 may be translated along the belt 109 under a knife-edge 107attached to a surface of the die 103. The knife-edge 107 may define aregion at the front of the die 103 that facilitates displacement of themixture 101 into the openings 152 of the screen 151.

Certain processing parameters may be controlled to facilitate theformation of particular features of the precursor shaped abrasiveparticles 123 and the finally-formed shaped abrasive particles describedherein. Some exemplary process parameters that can be controlled includea release distance 197, a viscosity of the mixture, a storage modulus ofthe mixture, mechanical properties of the bottom stage, geometric ordimensional characteristics of the bottom stage, thickness of thescreen, rigidity of the screen, a solid content of the mixture, acarrier content of the mixture, a release angle, a translation speed, atemperature, a content of release agent, a pressure exerted on themixture, a speed of the belt, and a combination thereof.

According to one embodiment, one particular process parameter caninclude controlling the release distance 197 between a filling positionand a release position. In particular, the release distance 197 can be adistance measured in a direction 110 of the translation of the belt 109between the end of the die 103 and the initial point of separationbetween the screen 151 and the belt 109. According to one embodiment,controlling the release distance 197 can affect at least one dimensionalcharacteristic of the precursor shaped abrasive particles 123 or thefinally-formed shaped abrasive particles. Moreover, control of therelease distance 197 can affect a combination of dimensionalcharacteristics of the shaped abrasive particles, including but notlimited to, length, width, interior height (hi), variation of interiorheight (Vhi), difference in height, profile ratio, flashing index,dishing index, rake angle, any of the dimensional characteristicvariations of the embodiments herein, and a combination thereof.

According to one embodiment, the release distance 197 can be not greaterthan a length of the screen 151. In other instances, the releasedistance 197 can be not greater than a width of the screen 151. Still,in one particular embodiment, the release distance 197 can be notgreater than 10 times a largest dimension of the opening 152 in thescreen 151. For example, the openings 152 can have a triangular shape,such as illustrated in FIG. 1B, and the release distance 197 can be notgreater than 10 times the length of one side of the opening 152 definingthe triangular shape. In other instances, the release distance 197 canbe less, such as not greater than about 8 times the largest dimension ofthe opening 152 in the screen 151, such as not greater than about 5times, not greater than about 3 times, not greater than about 2 times,or even not greater than the largest dimension of the opening 152 in thescreen 151.

In more particular instances, the release distance 197 can be notgreater than about 30 mm, such as not greater than about 20 mm, or evennot greater than about 10 mm. For at least one embodiment, the releasedistance can be substantially zero, and more particularly, can beessentially zero. Accordingly, the mixture 101 can be disposed into theopenings 152 within the application zone 183 and the screen 151 and thebelt 109 may be separating from each other at the end of the die 103 oreven before the end of the die 103.

According to one particular method of forming, the release distance 197can be essentially zero, which may facilitate substantially simultaneousfilling of the openings 152 with the mixture 101 and separation betweenthe belt 109 and the screen 151. For example, before the screen 151 andthe belt 109 pass the end of the die 103 and exit the application zone183, separation of the screen 151 and the belt 109 may be initiated. Inmore particular embodiments, separation between the screen 151 and thebelt 109 may be initiated immediately after the openings 152 are filledwith the mixture 101, prior to leaving the application zone 183 andwhile the screen 151 is located under the die 103. In still anotherembodiment, separation between the screen 151 and the belt 109 may beinitiated while the mixture 101 is being placed within the opening 152of the screen 151. In an alternative embodiment, separation between thescreen 151 and the belt 109 can be initiated before the mixture 101 isplaced in the openings 152 of the screen 151. For example, before theopenings 152 pass under the die opening 105, the belt 109 and screen 151are being separated, such that a gap exists between belt 109 and thescreen 151 while the mixture 101 is being forced into the openings 152.

For example, FIG. 2 illustrates a printing operation where the releasedistance 197 is substantially zero, and separation between the belt 109and the screen 151 is initiated before the belt 109 and screen 151 passunder the die opening 105. More particularly, the release between thebelt 109 and the screen 151 is initiated as the belt 109 and screen 151enter the application zone 183 and pass under the front of the die 103.Still, it will be appreciated that in some embodiments, separation ofthe belt 109 and screen 151 can occur before the belt 109 and screen 151enter the application zone 183 (defined by the front of the die 103),such that the release distance 197 may be a negative value.

Control of the release distance 197 can facilitate controlled formationof shaped abrasive particles having improved dimensional characteristicsand improved dimensional tolerances (e.g., low dimensionalcharacteristic variability). For example, decreasing the releasedistance 197 in combination with controlling other processing parameterscan facilitate improved formation of shaped abrasive particles havinggreater interior height (hi) values.

Additionally, as illustrated in FIG. 2, control of the separation height196 between a surface of the belt 109 and a lower surface 198 of thescreen 151 may facilitate controlled formation of shaped abrasiveparticles having improved dimensional characteristics and improveddimensional tolerances (e.g., low dimensional characteristicvariability). The separation height 196 may be related to the thicknessof the screen 151, the distance between the belt 109 and the die 103,and a combination thereof. Moreover, one or more dimensionalcharacteristics (e.g., interior height) of the precursor-shaped abrasiveparticles 123 may be controlled by controlling the separation height 196and the thickness of the screen 151. In particular instances, the screen151 can have an average thickness of not greater than about 700 microns,such as not greater than about 690 microns, not greater than about 680microns, not greater than about 670 microns, not greater than about 650microns, or not greater than about 640 microns. Still, the averagethickness of the screen can be at least about 100 microns, such as atleast about 300 microns, or even at least about 400 microns.

In one embodiment, the process of controlling can include a multi-stepprocess that can include measuring, calculating, adjusting, and acombination thereof. Such processes can be applied to the processparameter, a dimensional characteristic, a combination of dimensionalcharacteristics, and a combination thereof. For example, in oneembodiment, controlling can include measuring one or more dimensionalcharacteristics, calculating one or more values based on the process ofmeasuring the one or more dimensional characteristics, and adjusting oneor more process parameters (e.g., the release distance 197) based on theone or more calculated values. The process of controlling, andparticularly any of the processes of measuring, calculating, andadjusting, may be completed before, after, or during the formation ofthe shaped abrasive particles. In one particular embodiment, thecontrolling process can be a continuous process, wherein one or moredimensional characteristics are measured, and one or more processparameters are changed (i.e., adjusted) in response to the measureddimensional characteristics. For example, the process of controlling caninclude measuring a dimensional characteristic such as a difference inthe height of the precursor shaped abrasive particles 123, calculating adifference in height value of the precursor shaped abrasive particles123, and changing the release distance 197 to change the difference inheight value of the precursor shaped abrasive particles 123.

Referring again to FIG. 1, after extruding the mixture 101 into theopenings 152 of the screen 151, the belt 109 and the screen 151 may betranslated to a release zone 185 where the belt 109 and the screen 151can be separated to facilitate the formation of the precursor shapedabrasive particles 123. In accordance with an embodiment, the screen 151and the belt 109 may be separated from each other within the releasezone 185 at a particular release angle.

In fact, as illustrated, the precursor-shaped abrasive particles 123 maybe translated through a series of zones wherein various treatingprocesses may be conducted. Some suitable exemplary treating processescan include drying, heating, curing, reacting, radiating, mixing,stirring, agitating, planarizing, calcining, sintering, comminuting,sieving, doping, and a combination thereof. According to one embodiment,the precursor-shaped abrasive particles 123 may be translated through anoptional shaping zone 113, wherein at least one exterior surface of theparticles may be shaped as described in embodiments herein. Furthermore,the precursor-shaped abrasive particles 123 may be translated through anoptional application zone 131, wherein a dopant material can be appliedto at least one exterior surface of the particles as described inembodiments herein. And further, the precursor-shaped abrasive particles123 may be translated on the belt 109 through an optional post-formingzone 125, wherein a variety of processes, including, for example,drying, may be conducted on the precursor-shaped abrasive particles 123as described in embodiments herein.

The application zone 131 may be used for applying a material to at leastone exterior surface of one or more precursor-shaped abrasive particles123. In accordance with an embodiment, a dopant material may be appliedto the precursor-shaped abrasive particles 123. More particularly, asillustrated in FIG. 1, the application zone 131 can be positioned beforethe post-forming zone 125. As such, the process of applying a dopantmaterial may be completed on the precursor-shaped abrasive particles123. However, it will be appreciated that the application zone 131 maybe positioned in other places within the system 100. For example, theprocess of applying a dopant material can be completed after forming theprecursor-shaped abrasive particles 123, and more particularly, afterthe post-forming zone 125. In yet other instances, which will bedescribed in more detail herein, the process of applying a dopantmaterial may be conducted simultaneously with a process of forming theprecursor-shaped abrasive particles 123.

Within the application zone 131, a dopant material may be appliedutilizing various methods, including for example, spraying, dipping,depositing, impregnating, transferring, punching, cutting, pressing,crushing, and any combination thereof. In particular instances, theapplication zone 131 may utilize a spray nozzle, or a combination ofspray nozzles 132 and 133 to spray dopant material onto the precursorshaped abrasive particles 123.

In accordance with an embodiment, applying a dopant material can includethe application of a particular material, such as a precursor. Incertain instances, the precursor can be a salt, such as a metal salt,that includes a dopant material to be incorporated into thefinally-formed shaped abrasive particles. For example, the metal saltcan include an element or compound that is the precursor to the dopantmaterial. It will be appreciated that the salt material may be in liquidform, such as in a dispersion comprising the salt and liquid carrier.The salt may include nitrogen, and more particularly, can include anitrate. In other embodiments, the salt can be a chloride, sulfate,phosphate, and a combination thereof. In one embodiment, the salt caninclude a metal nitrate, and more particularly, consist essentially of ametal nitrate.

In one embodiment, the dopant material can include an element orcompound such as an alkali element, alkaline earth element, rare earthelement, hafnium, zirconium, niobium, tantalum, molybdenum, vanadium, ora combination thereof. In one particular embodiment, the dopant materialincludes an element or compound including an element such as lithium,sodium, potassium, magnesium, calcium, strontium, barium, scandium,yttrium, lanthanum, cesium, praseodymium, niobium, hafnium, zirconium,tantalum, molybdenum, vanadium, chromium, cobalt, iron, germanium,manganese, nickel, titanium, zinc, and a combination thereof.

In particular instances, the process of applying a dopant material caninclude selective placement of the dopant material on at least oneexterior surface of a precursor-shaped abrasive particle 123. Forexample, the process of applying a dopant material can include theapplication of a dopant material to an upper surface or a bottom surfaceof the precursor-shaped abrasive particles 123. In still anotherembodiment, one or more side surfaces of the precursor-shaped abrasiveparticles 123 can be treated such that a dopant material is appliedthereto. It will be appreciated that various methods may be used toapply the dopant material to various exterior surfaces of theprecursor-shaped abrasive particles 123. For example, a spraying processmay be used to apply a dopant material to an upper surface or sidesurface of the precursor-shaped abrasive particles 123. Still, in analternative embodiment, a dopant material may be applied to the bottomsurface of the precursor-shaped abrasive particles 123 through a processsuch as dipping, depositing, impregnating, or a combination thereof. Itwill be appreciated that a surface of the belt 109 may be treated withdopant material to facilitate a transfer of the dopant material to abottom surface of precursor-shaped abrasive particles 123.

After forming precursor-shaped abrasive particles 123, the particles maybe translated through a post-forming zone 125. Various processes may beconducted in the post-forming zone 125, including treatment of theprecursor-shaped abrasive particles 123. In one embodiment, thepost-forming zone 125 can include a heating process where theprecursor-shaped abrasive particles 123 may be dried. Drying may includethe removal of a particular content of material, including volatiles,such as water. In accordance with an embodiment, the drying process canbe conducted at a drying temperature of not greater than about 300° C.,such as not greater than about 280° C., or even not greater than about250° C. Still, in one non-limiting embodiment, the drying process may beconducted at a drying temperature of at least about 50° C. It will beappreciated that the drying temperature may be within a range betweenany of the minimum and maximum temperatures noted above. Furthermore,the precursor-shaped abrasive particles 123 may be translated throughthe post-forming zone 125 at a particular rate, such as at least about0.2 feet/min and not greater than about 8 feet/min.

Furthermore, the drying process may be conducted for a particularduration. For example, the drying process may be not greater than aboutsix hours.

After the precursor-shaped abrasive particles 123 are translated throughthe post-forming zone 125, the precursor-shaped abrasive particles 123may be removed from the belt 109. The precursor-shaped abrasiveparticles 123 may be collected in a bin 127 for further processing.

In accordance with an embodiment, the process of forming shaped abrasiveparticles may further comprise a sintering process. For certainprocesses of embodiments herein, sintering can be conducted aftercollecting the precursor-shaped abrasive particles 123 from the belt109. Alternatively, the sintering may be a process that is conductedwhile the precursor-shaped abrasive particles 123 are on the belt 109.Sintering of the precursor-shaped abrasive particles 123 may be utilizedto densify the particles, which are generally in a green state. In aparticular instance, the sintering process can facilitate the formationof a high-temperature phase of the ceramic material. For example, in oneembodiment, the precursor-shaped abrasive particles 123 may be sinteredsuch that a high-temperature phase of alumina, such as alpha-alumina, isformed. In one instance, a shaped abrasive particle can comprise atleast about 90 wt % alpha-alumina for the total weight of the particle.In other instances, the content of alpha alumina may be greater suchthat the shaped abrasive particle may consist essentially of alphaalumina.

Additionally, the body of the finally-formed shaped abrasive particlescan have particular two-dimensional shapes. For example, the body canhave a two-dimensional shape, as viewed in a plane defined by the lengthand width of the body, and can have a shape including a polygonal shape,ellipsoidal shape, a numeral, a Greek alphabet character, a Latinalphabet character, a Russian alphabet character, a complex shapeutilizing a combination of polygonal shapes and a combination thereof.Particular polygonal shapes include triangular, rectangular,trapezoidal, pentagonal, hexagonal, heptagonal, octagonal, nonagonal,decagonal, and any combination thereof. In another embodiment, the bodycan include a two-dimensional shape, as viewed in a plane defined by alength and a width of the body, including shapes selected from the groupconsisting of ellipsoids, Greek alphabet characters, Latin alphabetcharacters, Russian alphabet characters, and a combination thereof.

FIG. 3A includes a perspective view illustration of a shaped abrasiveparticle 300 in accordance with an embodiment. Additionally, FIG. 3Bincludes a cross-sectional illustration of the abrasive particle of FIG.3A. A body 301 of the shaped abrasive particle 300 includes an uppermajor surface 303 (i.e., a first major surface) and a bottom majorsurface 304 (i.e., a second major surface) opposite the upper majorsurface 303. The upper surface 303 and the bottom surface 304 can beseparated from each other by side surfaces 305, 306, and 307. Asillustrated, the body 301 of the shaped abrasive particle 300 can have agenerally triangular shape as viewed in a plane of the upper surface303. In particular, the body 301 can have a length (Lmiddle) as shown inFIG. 3B, which may be measured at the bottom surface 304 of the body 301as extending from a corner 313 through a midpoint 381 of the body 301 toa midpoint at the opposite edge 314 of the body. Alternatively, the body301 can be defined by a second length or profile length (Lp), which isthe measure of the dimension of the body 301 from a side view at theupper surface 303 from a first corner 313 to an adjacent corner 312.Notably, the dimension of Lmiddle can be a length defining a distancebetween a height at a corner (hc) and a height at a midpoint edge (hm)opposite the corner. The dimension Lp can be a profile length along aside of the particle 300 (as seen from a side view such as shown inFIGS. 2A and 2B) defining the distance between h1 and h2. Referenceherein to the length can refer to either Lmiddle or Lp.

The body 301 can further include a width (w) that is the longestdimension of the body 301 and extending along a side. The body 301 canfurther include a height (h), which may be a dimension of the body 301extending in a direction perpendicular to the length and width in adirection defined by a side surface of the body 301. Notably, as will bedescribed in more detail herein, the body 301 can be defined by variousheights depending upon the location on the body 301. In specificinstances, the width can be greater than or equal to the length, thelength can be greater than or equal to the height, and the width can begreater than or equal to the height.

Moreover, reference herein to any of the features of the embodimentsherein, including dimensional characteristic (e.g., h1, h2, hi, w,Lmiddle, Lp, and the like), can be reference to a dimension of a singleshaped abrasive particle of a batch, a median value, or an average valuederived from analysis of a suitable sampling of shaped abrasiveparticles from a batch. Unless stated explicitly, reference herein to adimensional characteristic can be considered a reference to a medianvalue that is based on a statistically significant value derived from asample size of a suitable number of particles from a batch of particles.Notably, for certain embodiments herein, the sample size can include atleast 10 randomly selected particles from a batch of particles. A batchof particles may include an amount of shaped abrasive particles suitablefor forming a commercial-grade abrasive product, such as at least about20 lbs. The batch of particles may be, but need not necessarily be, agroup of particles that are collected from a single process run.

In accordance with an embodiment, the body 301 of the shaped abrasiveparticle can have a first corner height (hc) at a first region of thebody defined by a corner 313. Notably, the corner 313 may represent thepoint of greatest height on the body 301; however, the height at thecorner 313 does not necessarily represent the point of greatest heighton the body 301. The corner 313 can be defined as a point or region onthe body 301 defined by the joining of the upper surface 303, and twoside surfaces 305 and 307. The body 301 may further include othercorners, spaced apart from each other, including for example, corner 311and corner 312. As further illustrated, the body 301 can include edges314, 315, and 316 that can be separated from each other by the corners311, 312, and 313. The edge 314 can be defined by an intersection of theupper surface 303 with the side surface 306. The edge 315 can be definedby an intersection of the upper surface 303 and side surface 305 betweencorners 311 and 313. The edge 316 can be defined by an intersection ofthe upper surface 303 and side surface 307 between corners 312 and 313.

As further illustrated, the body 301 can include a second midpointheight (hm) at a second end of the body 301, which can be defined by aregion at the midpoint of the edge 314, which can be opposite the firstend defined by the corner 313. The axis 350 can extend between the twoends of the body 301. FIG. 3B is a cross-sectional illustration of thebody 301 along the axis 350, which can extend through a midpoint 381 ofthe body 301 along the dimension of length (Lmiddle) between the corner313 and the midpoint of the edge 314.

In accordance with an embodiment, the shaped abrasive particles of theembodiments herein, including for example, the particle of FIGS. 3A and3B can have an average difference in height, which is a measure of thedifference between hc and hm. For convention herein, average differencein height will be generally identified as hc-hm, however it is definedas an absolute value of the difference. Therefore, it will beappreciated that average difference in height may be calculated as hm−hcwhen the height of the body 301 at the midpoint of the edge 314 isgreater than the height at the corner 313. More particularly, theaverage difference in height can be calculated based upon a plurality ofshaped abrasive particles from a suitable sample size. The heights hcand hm of the particles can be measured using a STIL (Sciences etTechniques Industrielles de la Lumiere—France) Micro Measure 3D SurfaceProfilometer (white light (LED) chromatic aberration technique) and theaverage difference in height can be calculated based on the averagevalues of hc and hm from the sample.

As illustrated in FIG. 3B, in one particular embodiment, the body 301 ofthe shaped abrasive particle 300 may have an average difference inheight at different locations at the body 301. The body 301 can have anaverage difference in height, which can be the absolute value of [hc−hm]between the first corner height (hc) and the second midpoint height (hm)that is at least about 20 microns. It will be appreciated that averagedifference in height may be calculated as hm−hc when the height of thebody 301 at a midpoint of the edge is greater than the height at anopposite corner. In other instances, the average difference in height[hc−hm] can be at least about 25 microns, at least about 30 microns, atleast about 36 microns, at least about 40 microns, at least about 60microns, such as at least about 65 microns, at least about 70 microns,at least about 75 microns, at least about 80 microns, at least about 90microns, or even at least about 100 microns. In one non-limitingembodiment, the average difference in height can be not greater thanabout 300 microns, such as not greater than about 250 microns, notgreater than about 220 microns, or even not greater than about 180microns. It will be appreciated that the average difference in heightcan be within a range between any of the minimum and maximum valuesnoted above. Moreover, it will be appreciated that the averagedifference in height can be based upon an average value of hc. Forexample, the average height of the body 301 at the corners (Ahc) can becalculated by measuring the height of the body 301 at all corners andaveraging the values, and may be distinct from a single value of heightat one corner (hc). Accordingly, the average difference in height may begiven by the absolute value of the equation [Ahc−hi]. Furthermore, itwill be appreciated that the average difference in height can becalculated using a median interior height (Mhi) calculated from asuitable sample size from a batch of shaped abrasive particles and anaverage height at the corners for all particles in the sample size.Accordingly, the average difference in height may be given by theabsolute value of the equation [Ahc−Mhi].

In particular instances, the body 301 can be formed to have a primaryaspect ratio, which is a ratio expressed as width:length, having a valueof at least 1:1. In other instances, the body 301 can be formed suchthat the primary aspect ratio (w:1) is at least about 1.5:1, such as atleast about 2:1, at least about 4:1, or even at least about 5:1. Still,in other instances, the abrasive particle 300 can be formed such thatthe body 301 has a primary aspect ratio that is not greater than about10:1, such as not greater than 9:1, not greater than about 8:1, or evennot greater than about 5:1. It will be appreciated that the body 301 canhave a primary aspect ratio within a range between any of the ratiosnoted above. Furthermore, it will be appreciated that reference hereinto a height can be a reference to the maximum height measurable of theabrasive particle 300. It will be described later that the abrasiveparticle 300 may have different heights at different positions withinthe body 301 of the abrasive particle 300.

In addition to the primary aspect ratio, the abrasive particle 300 canbe formed such that the body 301 comprises a secondary aspect ratio,which can be defined as a ratio of length:height, wherein the height isan interior median height (Mhi). In certain instances, the secondaryaspect ratio can be at least about 1:1, such as at least about 2:1, atleast about 4:1, or even at least about 5:1. Still, in other instances,the abrasive particle 300 can be formed such that the body 301 has asecondary aspect ratio that is not greater than about 1:3, such as notgreater than 1:2, or even not greater than about 1:1. It will beappreciated that the body 301 can have a secondary aspect ratio within arange between any of the ratios noted above, such as within a rangebetween about 5:1 and about 1:1.

In accordance with another embodiment, the abrasive particle 300 can beformed such that the body 301 comprises a tertiary aspect ratio, definedby the ratio width:height, wherein the height is an interior medianheight (Mhi). The tertiary aspect ratio of the body 301 can be can be atleast about 1:1, such as at least about 2:1, at least about 4:1, atleast about 5:1, or even at least about 6:1. Still, in other instances,the abrasive particle 300 can be formed such that the body 301 has atertiary aspect ratio that is not greater than about 3:1, such as notgreater than 2:1, or even not greater than about 1:1. It will beappreciated that the body 301 can have a tertiary aspect ratio within arange between any of the ratios noted above, such as within a rangebetween about 6:1 and about 1:1.

According to one embodiment, the body 301 of the shaped abrasiveparticle 300 can have particular dimensions, which may facilitateimproved performance. For example, in one instance, the body 301 canhave an interior height (hi), which can be the smallest dimension ofheight of the body 301 as measured along a dimension between any cornerand opposite midpoint edge on the body 301. In particular instances,wherein the body 301 is a generally triangular two-dimensional shape,the interior height (hi) may be the smallest dimension of height (i.e.,measure between the bottom surface 304 and the upper surface 305) of thebody 301 for three measurements taken between each of the three cornersand the opposite midpoint edges. The interior height (hi) of the body301 of a shaped abrasive particle 300 is illustrated in FIG. 3B.According to one embodiment, the interior height (hi) can be at leastabout 20% of the width (w). The height (hi) may be measured bysectioning or mounting and grinding the shaped abrasive particle 300 andviewing in a manner sufficient (e.g., light microscope or SEM) todetermine the smallest height (hi) within the interior of the body 301.In one particular embodiment, the height (hi) can be at least about 22%of the width, such as at least about 25%, at least about 30%, or even atleast about 33%, of the width of the body 301. For one non-limitingembodiment, the height (hi) of the body 301 can be not greater thanabout 80% of the width of the body 301, such as not greater than about76%, not greater than about 73%, not greater than about 70%, not greaterthan about 68% of the width, not greater than about 56% of the width,not greater than about 48% of the width, or even not greater than about40% of the width. It will be appreciated that the height (hi) of thebody 301 can be within a range between any of the above-noted minimumand maximum percentages.

A batch of shaped abrasive particles can be fabricated, wherein themedian interior height value (Mhi) can be controlled, which mayfacilitate improved performance. In particular, the median internalheight (hi) of a batch can be related to a median width of the shapedabrasive particles of the batch in the same manner as described above.Notably, the median interior height (Mhi) can be at least about 20% ofthe width, such as at least about 22%, at least about 25%, at leastabout 30%, or even at least about 33% of the median width of the shapedabrasive particles of the batch. For one non-limiting embodiment, themedian interior height (Mhi) of the body 301 can be not greater thanabout 80%, such as not greater than about 76%, not greater than about73%, not greater than about 70%, not greater than about 68% of thewidth, not greater than about 56% of the width, not greater than about48% of the width, or even not greater than about 40% of the median widthof the body 301. It will be appreciated that the median interior height(Mhi) of the body 301 can be within a range between any of theabove-noted minimum and maximum percentages.

Furthermore, the batch of shaped abrasive particles may exhibit improveddimensional uniformity as measured by the standard deviation of adimensional characteristic from a suitable sample size. According to oneembodiment, the shaped abrasive particles can have an interior heightvariation (Vhi), which can be calculated as the standard deviation ofinterior height (hi) for a suitable sample size of particles from abatch. According to one embodiment, the interior height variation can benot greater than about 60 microns, such as not greater than about 58microns, not greater than about 56 microns, or even not greater thanabout 54 microns. In one non-limiting embodiment, the interior heightvariation (Vhi) can be at least about 2 microns. It will be appreciatedthat the interior height variation of the body can be within a rangebetween any of the above-noted minimum and maximum values.

For another embodiment, the body 301 of the shaped abrasive particle 300can have an interior height (hi) of at least about 400 microns. Moreparticularly, the height may be at least about 450 microns, such as atleast about 475 microns, or even at least about 500 microns. In stillone non-limiting embodiment, the height of the body 301 can be notgreater than about 3 mm, such as not greater than about 2 mm, notgreater than about 1.5 mm, not greater than about 1 mm, or even notgreater than about 800 microns. It will be appreciated that the heightof the body 301 can be within a range between any of the above-notedminimum and maximum values. Moreover, it will be appreciated that theabove range of values can be representative of a median interior height(Mhi) value for a batch of shaped abrasive particles.

For certain embodiments herein, the body 301 of the shaped abrasiveparticle 300 can have particular dimensions, including, for example, awidth≥length, a length≥height, and a width≥height. More particularly,the body 301 of the shaped abrasive particle 300 can have a width (w) ofat least about 600 microns, such as at least about 700 microns, at leastabout 800 microns, or even at least about 900 microns. In onenon-limiting instance, the body 301 can have a width of not greater thanabout 4 mm, such as not greater than about 3 mm, not greater than about2.5 mm, or even not greater than about 2 mm. It will be appreciated thatthe width of the body 301 can be within a range between any of theabove-noted minimum and maximum values. Moreover, it will be appreciatedthat the above range of values can be representative of a median width(Mw) for a batch of shaped abrasive particles.

The body 301 of the shaped abrasive particle 300 can have particulardimensions, including, for example, a length (L middle or Lp) of atleast about 0.4 mm, such as at least about 0.6 mm, at least about 0.8mm, or even at least about 0.9 mm. Still, for at least one non-limitingembodiment, the body 301 can have a length of not greater than about 4mm, such as not greater than about 3 mm, not greater than about 2.5 mm,or even not greater than about 2 mm. It will be appreciated that thelength of the body 301 can be within a range between any of theabove-noted minimum and maximum values. Moreover, it will be appreciatedthat the above range of values can be representative of a median length(Ml), which may be more particularly, a median middle length (MLmiddle)or median profile length (MLp) for a batch of shaped abrasive particles.

The shaped abrasive particle 300 can have a body 301 having a particularamount of dishing, wherein the dishing value (d) can be defined as aratio between an average height of the body 301 at the corners (Ahc) ascompared to the smallest dimension of height of the body 301 at theinterior (hi). The average height of the body 301 at the corners (Ahc)can be calculated by measuring the height of the body 301 at all cornersand averaging the values, and may be distinct from a single value ofheight at one corner (hc). The average height of the body 301 at thecorners or at the interior can be measured using a STIL (Sciences etTechniques Industrielles de la Lumiere—France) Micro Measure 3D SurfaceProfilometer (white light (LED) chromatic aberration technique).Alternatively, the dishing may be based upon a median height of theparticles at the corner (Mhc) calculated from a suitable sampling ofparticles from a batch. Likewise, the interior height (hi) can be amedian interior height (Mhi) derived from a suitable sampling of shapedabrasive particles from a batch. According to one embodiment, thedishing value (d) can be not greater than about 2, such as not greaterthan about 1.9, not greater than about 1.8, not greater than about 1.7,not greater than about 1.6, not greater than about 1.5, or even notgreater than about 1.2. Still, in at least one non-limiting embodiment,the dishing value (d) can be at least about 0.9, such as at least about1.0. It will be appreciated that the dishing ratio can be within a rangebetween any of the minimum and maximum values noted above. Moreover, itwill be appreciated that the above dishing values can be representativeof a median dishing value (Md) for a batch of shaped abrasive particles.

The shaped abrasive particles of the embodiments herein, including forexample, the body 301 of the particle of FIG. 3A can have a bottomsurface 304 defining a bottom area (A_(b)). In particular instances, thebottom surface 304 can be the largest surface of the body 301. Thebottom major surface 304 can have a surface area defined as the bottomarea (A_(b)) that is different than the surface area of the upper majorsurface 303. In one particular embodiment, the bottom major surface 304can have a surface area defined as the bottom area (A_(b)) that isdifferent than the surface area of the upper major surface 303. Inanother embodiment, the bottom major surface 304 can have a surface areadefined as the bottom area (A_(b)) that is less than the surface area ofthe upper major surface 303.

Additionally, the body 301 can have a cross-sectional midpoint area(A_(m)) defining an area of a plane perpendicular to the bottom area(A_(b)) and extending through a midpoint 381 of the particle 300. Incertain instances, the body 301 can have an area ratio of bottom area tomidpoint area (A_(b)/A_(m)) of not greater than about 6. In moreparticular instances, the area ratio can be not greater than about 5.5,such as not greater than about 5, not greater than about 4.5, notgreater than about 4, not greater than about 3.5, or even not greaterthan about 3. Still, in one non-limiting embodiment, the area ratio maybe at least about 1.1, such as at least about 1.3, or even at leastabout 1.8. It will be appreciated that the area ratio can be within arange between any of the minimum and maximum values noted above.Moreover, it will be appreciated that the above area ratios can berepresentative of a median area ratio for a batch of shaped abrasiveparticles.

Furthermore the shaped abrasive particles of the embodiments hereinincluding, for example, the particle of FIG. 3B, can have a normalizedheight difference of not greater than about 0.3. The normalized heightdifference can be defined by the absolute value of the equation[(hc−hm)/(hi)]. In other embodiments, the normalized height differencecan be not greater than about 0.26, such as not greater than about 0.22,or even not greater than about 0.19. Still, in one particularembodiment, the normalized height difference can be at least about 0.04,such as at least about 0.05, or even at least about 0.06. It will beappreciated that the normalized height difference can be within a rangebetween any of the minimum and maximum values noted above. Moreover, itwill be appreciated that the above-normalized height values can berepresentative of a median normalized height value for a batch of shapedabrasive particles.

In another instance, the body 301 can have a profile ratio of at leastabout 0.04, wherein the profile ratio is defined as a ratio of theaverage difference in height [hc−hm] to the length (Lmiddle) of theshaped abrasive particle 300, defined as the absolute value of[(hc−hm)/(Lmiddle)]. It will be appreciated that the length (Lmiddle) ofthe body 301 can be the distance across the body 301 as illustrated inFIG. 3B. Moreover, the length may be an average or median lengthcalculated from a suitable sampling of particles from a batch of shapedabrasive particles as defined herein. According to a particularembodiment, the profile ratio can be at least about 0.05, at least about0.06, at least about 0.07, at least about 0.08, or even at least about0.09. Still, in one non-limiting embodiment, the profile ratio can benot greater than about 0.3, such as not greater than about 0.2, notgreater than about 0.18, not greater than about 0.16, or even notgreater than about 0.14. It will be appreciated that the profile ratiocan be within a range between any of the minimum and maximum valuesnoted above. Moreover, it will be appreciated that the above profileratio can be representative of a median profile ratio for a batch ofshaped abrasive particles.

According to another embodiment, the body 301 can have a particular rakeangle, which may be defined as an angle between the bottom surface 304and a side surface 305, 306, or 307 of the body 301. For example, therake angle may be within a range between about 1° and about 80°. Forother particles herein, the rake angle can be within a range betweenabout 5° and 55°, such as between about 10° and about 50°, between about15° and 50°, or even between about 20° and 50°. The formation of anabrasive particle having such a rake angle can improve the abradingcapabilities of the abrasive particle 300. Notably, the rake angle canbe within a range between any two rake angles noted above.

According to another embodiment, the shaped abrasive particles hereinincluding, for example, the particles of FIGS. 3A and 3 B, can have anellipsoidal region 317 in the upper surface 303 of the body 301. Theellipsoidal region 317 can be defined by a trench region 318 that canextend around the upper surface 303 and define the ellipsoidal region317. The ellipsoidal region 317 can encompass the midpoint 381.Moreover, it is thought that the ellipsoidal region 317 defined in theupper surface 303 can be an artifact of the forming process, and may beformed as a result of the stresses imposed on the mixture 101 duringformation of the shaped abrasive particles according to the methodsdescribed herein.

The shaped abrasive particle 300 can be formed such that the body 301includes a crystalline material, and more particularly, apolycrystalline material. Notably, the polycrystalline material caninclude abrasive grains. In one embodiment, the body 301 can beessentially free of an organic material, including, for example, abinder. More particularly, the body 301 can consist essentially of apolycrystalline material.

In one aspect, the body 301 of the shaped abrasive particle 300 can bean agglomerate including a plurality of abrasive particles, grit, and/orgrains bonded to each other to form the body 301 of the abrasiveparticle 300. Suitable abrasive grains can include nitrides, oxides,carbides, borides, oxynitrides, oxyborides, diamond, and a combinationthereof. In particular instances, the abrasive grains can include anoxide compound or complex, such as aluminum oxide, zirconium oxide,titanium oxide, yttrium oxide, chromium oxide, strontium oxide, siliconoxide, and a combination thereof. In one particular instance, theabrasive particle 300 is formed such that the abrasive grains formingthe body 301 include alumina, and more particularly, may consistessentially of alumina. Moreover, in particular instances, the shapedabrasive particle 300 can be formed from a seeded sol-gel.

The abrasive grains (i.e., crystallites) contained within the body 301may have an average grain size that is generally not greater than about100 microns. In other embodiments, the average grain size can be less,such as not greater than about 80 microns, not greater than about 50microns, not greater than about 30 microns, not greater than about 20microns, not greater than about 10 microns, or even not greater thanabout 1 micron. Still, the average grain size of the abrasive grainscontained within the body 301 can be at least about 0.01 microns, suchas at least about 0.05 microns, such as at least about 0.08 microns, atleast about 0.1 microns, or even at least about 0.5 microns. It will beappreciated that the abrasive grains can have an average grain sizewithin a range between any of the minimum and maximum values notedabove.

In accordance with certain embodiments, the abrasive particle 300 can bea composite article including at least two different types of grainswithin the body 301. It will be appreciated that different types ofgrains are grains having different compositions with regard to eachother. For example, the body 301 can be formed such that is includes atleast two different types of grains, wherein the two different types ofgrains can be nitrides, oxides, carbides, borides, oxynitrides,oxyborides, diamond, and a combination thereof.

In accordance with an embodiment, the abrasive particle 300 can have anaverage particle size, as measured by the largest dimension measurableon the body 301, of at least about 100 microns. In fact, the abrasiveparticle 300 can have an average particle size of at least about 150microns, such as at least about 200 microns, at least about 300 microns,at least about 400 microns, at least about 500 microns, at least about600 microns, at least about 700 microns, at least about 800 microns, oreven at least about 900 microns. Still, the abrasive particle 300 canhave an average particle size that is not greater than about 5 mm, suchas not greater than about 3 mm, not greater than about 2 mm, or even notgreater than about 1.5 mm. It will be appreciated that the abrasiveparticle 300 can have an average particle size within a range betweenany of the minimum and maximum values noted above.

The shaped abrasive particles of the embodiments herein can have apercent flashing that may facilitate improved performance. Notably, theflashing defines an area of the particle as viewed along one side, suchas illustrated in FIG. 4, wherein the flashing extends from a sidesurface of the body 301 within the boxes 402 and 403. The flashing canrepresent tapered regions proximate to the upper surface 303 and bottomsurface 304 of the body 301. The flashing can be measured as thepercentage of area of the body 301 along the side surface containedwithin a box extending between an innermost point of the side surface(e.g., 421) and an outermost point (e.g., 422) on the side surface ofthe body 301. In one particular instance, the body 301 can have aparticular content of flashing, which can be the percentage of area ofthe body 301 contained within the boxes 402 and 403 compared to thetotal area of the body 301 contained within boxes 402, 403, and 404.According to one embodiment, the percent flashing (f) of the body 301can be at least about 1%. In another embodiment, the percent flashingcan be greater, such as at least about 2%, at least about 3%, at leastabout 5%, at least about 8%, at least about 10%, at least about 12%,such as at least about 15%, at least about 18%, or even at least about20%. Still, in a non-limiting embodiment, the percent flashing of thebody 301 can be controlled and may be not greater than about 45%, suchas not greater than about 40%, not greater than about 35%, not greaterthan about 30%, not greater than about 25%, not greater than about 20%,not greater than about 18%, not greater than about 15%, not greater thanabout 12%, not greater than about 10%, not greater than about 8%, notgreater than about 6%, or even not greater than about 4%. It will beappreciated that the percent flashing of the body 301 can be within arange between any of the above minimum and maximum percentages.Moreover, it will be appreciated that the above flashing percentages canbe representative of an average flashing percentage or a median flashingpercentage for a batch of shaped abrasive particles.

The percent flashing can be measured by mounting the shaped abrasiveparticle 300 on its side and viewing the body 301 at the side togenerate a black and white image, such as illustrated in FIG. 4. Asuitable program for such includes ImageJ software. The percentageflashing can be calculated by determining the area of the body 301 inthe boxes 402 and 403 compared to the total area of the body 301 asviewed at the side (total shaded area), including the area in the center404 and within the boxes. Such a procedure can be completed for asuitable sampling of particles to generate average, median, and/or andstandard deviation values.

A batch of shaped abrasive particles, according to embodiments herein,may exhibit improved dimensional uniformity as measured by the standarddeviation of a dimensional characteristic from a suitable sample size.According to one embodiment, the shaped abrasive particles can have aflashing variation (Vf), which can be calculated as the standarddeviation of flashing percentage (f) for a suitable sample size ofparticles from a batch. According to one embodiment, the flashingvariation can be not greater than about 5.5%, such as not greater thanabout 5.3%, not greater than about 5%, or not greater than about 4.8%,not greater than about 4.6%, or even not greater than about 4.4%. In onenon-limiting embodiment, the flashing variation (Vf) can be at leastabout 0.1%. It will be appreciated that the flashing variation can bewithin a range between any of the minimum and maximum percentages notedabove.

The shaped abrasive particles of the embodiments herein can have aheight (hi) and flashing multiplier value (hiF) of at least 4000,wherein hiF=(hi)(f), an “hi” represents a minimum interior height of thebody 301 as described above and “f” represents the percent flashing. Inone particular instance, the height and flashing multiplier value (hiF)of the body 301 can be greater, such as at least about 4500 micron %, atleast about 5000 micron %, at least about 6000 micron %, at least about7000 micron %, or even at least about 8000 micron %. Still, in onenon-limiting embodiment, the height and flashing multiplier value can benot greater than about 45000 micron %, such as not greater than about30000 micron %, not greater than about 25000 micron %, not greater thanabout 20000 micron %, or even not greater than about 18000 micron %. Itwill be appreciated that the height and flashing multiplier value of thebody 301 can be within a range between any of the above minimum andmaximum values. Moreover, it will be appreciated that the abovemultiplier value can be representative of a median multiplier value(MhiF) for a batch of shaped abrasive particles.

A Fixed Abrasive Article

After forming or sourcing the shaped abrasive particles, the particlescan be combined with other materials to form a fixed abrasive article.Some suitable exemplary fixed abrasive articles can include bondedabrasive articles wherein the shaped abrasive particles are contained ina three-dimensional matrix of bond material, and coated abrasivearticles, wherein the shaped abrasive particles may be dispersed in asingle-layer overlying a backing and bonded to the backing using one ormore adhesive layers. , the particles may be combined with a backing toform a coated abrasive article.

FIG. 5 includes a cross-sectional illustration of a coated abrasivearticle in accordance with an embodiment. In particular, coated abrasivearticle 500 can include a substrate 501 (i.e., a backing) and at leastone adhesive layer overlying a surface of the substrate 501. Theadhesive layer can include a make coat 503 and/or a size coat 504. Thecoated abrasive 500 can include abrasive particulate material 510, whichcan include shaped abrasive particles 505 of the embodiments herein, anda second type of abrasive particulate material 507 in the form ofdiluent abrasive particles having a random shape, which may notnecessarily be shaped abrasive particles. The make coat 503 can beoverlying the surface of the substrate 501 and surrounding at least aportion of the shaped abrasive particles 505 and a second type ofabrasive particulate material 507. The size coat 504 can be overlyingand bonded to the shaped abrasive particles 505 and a second type ofabrasive particulate material 507 and the make coat 503.

According to one embodiment, the substrate 501 can include an organicmaterial, inorganic material, and a combination thereof. In certaininstances, the substrate 501 can include a woven material. However, thesubstrate 501 may be made of a non-woven material. Particularly suitablesubstrate materials can include organic materials, including polymers,and particularly, polyester, polyurethane, polypropylene, polyimidessuch as KAPTON from DuPont, paper. Some suitable inorganic materials caninclude metals, metal alloys, and particularly, foils of copper,aluminum, steel, and a combination thereof.

A polymer formulation may be used to form any of a variety of layers ofthe abrasive article, such as, for example, a frontfill, a pre-size, themake coat, the size coat, and/or a supersize coat. When used to form thefrontfill, the polymer formulation generally includes a polymer resin,fibrillated fibers (preferably in the form of pulp), filler material,and other optional additives. Suitable formulations for some frontfillembodiments can include material such as a phenolic resin, wollastonitefiller, defoamer, surfactant, a fibrillated fiber, and a balance ofwater. Suitable polymeric resin materials include curable resinsselected from thermally curable resins, including phenolic resins,urea/formaldehyde resins, phenolic/latex resins, as well as combinationsof such resins. Other suitable polymeric resin materials may alsoinclude radiation curable resins, such as those resins curable usingelectron beam, UV radiation, or visible light, such as epoxy resins,acrylated oligomers of acrylated epoxy resins, polyester resins,acrylated urethanes, and polyester acrylates, and acrylated monomersincluding monoacrylated, multiacrylated monomers. The formulation canalso comprise a nonreactive thermoplastic resin binder which can enhancethe self-sharpening characteristics of the deposited abrasive particlesby enhancing the erodability. Examples of such thermoplastic resininclude polypropylene glycol, polyethylene glycol, andpolyoxypropylene-polyoxyethene block copolymer, etc. Use of a frontfillon the substrate 501 can improve the uniformity of the surface forsuitable application of the make coat 503 and improved application andorientation of shaped abrasive particles 505 in a predeterminedorientation.

The make coat 503 can be applied to the surface of the substrate 501 ina single process, or alternatively, the abrasive particulate material510 can be combined with a make coat 503 material and applied as amixture to the surface of the substrate 501. Suitable materials of themake coat 503 can include organic materials, particularly polymericmaterials, including, for example, polyesters, epoxy resins,polyurethanes, polyamides, polyacrylates, polymethacrylates, polyvinylchlorides, polyethylene, polysiloxane, silicones, cellulose acetates,nitrocellulose, natural rubber, starch, shellac, and mixtures thereof.In one embodiment, the make coat 503 can include a polyester resin. Thecoated substrate can then be heated in order to cure the resin and theabrasive particulate material to the substrate. In general, the coatedsubstrate 501 can be heated to a temperature of between about 100° C. toless than about 250° C. during this curing process.

The abrasive particulate material 510 can include shaped abrasiveparticles 505 according to embodiments herein. In particular instances,the abrasive particulate material 510 may include different types ofshaped abrasive particles 505. The different types of shaped abrasiveparticles can differ from each other in composition, in two-dimensionalshape, in three-dimensional shape, in size, and a combination thereof asdescribed in the embodiments herein. As illustrated, the coated abrasive500 can include a shaped abrasive particle 505 having a generallytriangular two-dimensional shape.

The other type of abrasive particles 507 can be diluent particlesdifferent than the shaped abrasive particles 505. For example, thediluent particles can differ from the shaped abrasive particles 505 incomposition, in two-dimensional shape, in three-dimensional shape, insize, and a combination thereof. For example, the abrasive particles 507can represent conventional, crushed abrasive grit having random shapes.The abrasive particles 507 may have a median particle size less than themedian particle size of the shaped abrasive particles 505.

After sufficiently forming the make coat 503 with the abrasiveparticulate material 510, the size coat 504 can be formed to overlie andbond the abrasive particulate material 510 in place. The size coat 504can include an organic material, may be made essentially of a polymericmaterial, and notably, can use polyesters, epoxy resins, polyurethanes,polyamides, polyacrylates, polymethacrylates, poly vinyl chlorides,polyethylene, polysiloxane, silicones, cellulose acetates,nitrocellulose, natural rubber, starch, shellac, and mixtures thereof.

According to one embodiment, the shaped abrasive particles 505 hereincan be oriented in a predetermined orientation relative to each otherand the substrate 501. While not completely understood, it is thoughtthat one or a combination of dimensional features may be responsible forimproved orientation of the shaped abrasive particles 505. According toone embodiment, the shaped abrasive particles 505 can be oriented in aflat orientation relative to the substrate 501, such as that shown inFIG. 5. In the flat orientation, the bottom surface 304 of the shapedabrasive particles can be closest to a surface of the substrate 501(i.e., the backing), and the upper surface 303 of the shaped abrasiveparticles 505 can be directed away from the substrate 501 and configuredto conduct initial engagement with a workpiece.

According to another embodiment, the shaped abrasive particles 505 canbe placed on a substrate 501 in a predetermined side orientation, suchas that shown in FIG. 6. In particular instances, a majority of theshaped abrasive particles 505 of the total content of shaped abrasiveparticles 505 on the abrasive article 500 can have a predetermined andside orientation. In the side orientation, the bottom surface 304 of theshaped abrasive particles 505 can be spaced away and angled relative tothe surface of the substrate 501. In particular instances, the bottomsurface 304 can form an obtuse angle (B) relative to the surface of thesubstrate 501. Moreover, the upper surface 303 is spaced away and angledrelative to the surface of the substrate 501, which in particularinstances may define a generally acute angle (A). In a side orientation,a side surface (305, 306, or 307) can be closest to the surface of thesubstrate 501, and more particularly, may be in direct contact with asurface of the substrate 501.

For certain other abrasive articles herein, at least about 55% of theplurality of shaped abrasive particles 505 on the abrasive article 500can have a predetermined side orientation. Still, the percentage may begreater, such as at least about 60%, at least about 65%, at least about70%, at least about 75%, at least about 77%, at least about 80%, atleast about 81%, or even at least about 82%. And for one non-limitingembodiment, an abrasive article 500 may be formed using the shapedabrasive particles 505 herein, wherein not greater than about 99% of thetotal content of shaped abrasive particles have a predetermined sideorientation.

To determine the percentage of particles in a predetermined orientation,a 2D microfocus x-ray image of the abrasive article 500 is obtainedusing a CT scan machine run in the conditions of Table 1 below. TheX-ray 2D imaging was conducted on RB214 with Quality Assurance software.A specimen mounting fixture utilizes a plastic frame with a 4″×4″ windowand an Ø0.5″ solid metallic rod, the top part of which is half flattenedwith two screws to fix the frame. Prior to imaging, a specimen wasclipped over one side of the frame where the screw heads were faced withthe incidence direction of the X-rays. Then five regions within the4″×4″ window area are selected for imaging at 120 kV/80 μA. Each 2Dprojection was recorded with the X-ray off-set/gain corrections and at amagnification of 15 times.

TABLE 1 Field of view per Voltage Current image Exposure (kV) (μA)Magnification (mm × mm) time 120 80 15X 16.2 × 13.0 500 ms/ 2.0 fps

The image is then imported and analyzed using the ImageJ program,wherein different orientations are assigned values according to Table 2below. FIG. 13 includes images representative of portions of a coatedabrasive according to an embodiment and used to analyze the orientationof shaped abrasive particles on the backing.

TABLE 2 Cell marker type Comments 1 Grains on the perimeter of theimage, partially exposed - standing up 2 Grains on the perimeter of theimage, partially exposed - down 3 Grains on the image, completelyexposed - standing vertical 4 Grains on the image, completely exposed -down 5 Grains on the image, completely exposed - standing slanted(between standing vertical and down)

Three calculations are then performed as provided below in Table 3.After conducting the calculations, the percentage of grains in aparticular orientation (e.g., side orientation) per square centimetercan be derived.

TABLE 3 5) Parameter Protocol* % grains up ((0.5 × 1) + 3 + 5)/ (1 + 2 +3 + 4 + 5) Total # of grains (1 + 2 + 3 + 4 + 5) per cm² # of grains up(% grains up × Total # of grains per cm² per cm² *These are allnormalized with respect to the representative area of the image. +Ascale factor of 0.5 was applied to account for the fact that they arenot completely present in the image.

Furthermore, the abrasive articles made with the shaped abrasiveparticles can utilize various contents of the shaped abrasive particles.For example, the abrasive articles can be coated abrasive articlesincluding a single layer of the shaped abrasive particles in anopen-coat configuration or a closed-coat configuration. For example, theplurality of shaped abrasive particles can define an open-coat abrasiveproduct having a coating density of shaped abrasive particles of notgreater than about 70 particles/cm². In other instances, the open-coatdensity of shaped abrasive particle per square centimeter of abrasivearticle may be not greater than about 65 particles/cm², such as notgreater than about 60 particles/cm², not greater than about 55particles/cm², or even not greater than about 50 particles/cm². Still,in one non-limiting embodiment, the density of the open-coat coatedabrasive using the shaped abrasive particle herein can be at least about5 particles/cm², or even at least about 10 particles/cm². It will beappreciated that the open-coat density of the coated abrasive articlecan be within a range between any of the above minimum and maximumvalues.

In an alternative embodiment, the plurality of shaped abrasive particlescan define a closed-coat abrasive product having a coating density ofshaped abrasive particles of at least about 75 particles/cm², such as atleast about 80 particles/cm², at least about 85 particles/cm², at leastabout 90 particles/cm², at least about 100 particles/cm². Still, in onenon-limiting embodiment, the closed-coat density of the coated abrasiveusing the shaped abrasive particle herein can be not greater than about500 particles/cm². It will be appreciated that the closed coat densityof the coated abrasive article can be within a range between any of theabove minimum and maximum values.

In certain instances, the abrasive article can have an open-coat densityof a coating not greater than about 50% of abrasive particles coveringthe exterior abrasive surface of the article. In other embodiments, thepercentage coating of the abrasive particles relative to the total areaof the abrasive surface can be not greater than about 40%, not greaterthan about 30%, not greater than about 25%, or even not greater thanabout 20%. Still, in one non-limiting embodiment, the percentage coatingof the abrasive particles relative to the total area of the abrasivesurface can be at least about 5%, such as at least about 10%, at leastabout 15%, at least about 20%, at least about 25%, at least about 30%,at least about 35%, or even at least about 40%. It will be appreciatedthat the percent coverage of shaped abrasive particles for the totalarea of abrasive surface can be within a range between any of the aboveminimum and maximum values.

Some abrasive articles may have a particular content of abrasiveparticles for a length (e.g., ream) of the backing or the substrate 501.For example, in one embodiment, the abrasive article may utilize anormalized weight of shaped abrasive particles of at least about 20lbs/ream, such as at least about 25 lbs/ream, or even at least about 30lbs/ream. Still, in one non-limiting embodiment, the abrasive articlescan include a normalized weight of shaped abrasive particles of notgreater than about 60 lbs/ream, such as not greater than about 50lbs/ream, or even not greater than about 45 lbs/ream. It will beappreciated that the abrasive articles of the embodiments herein canutilize a normalized weight of shaped abrasive particles within a rangebetween any of the above minimum and maximum values.

The plurality of shaped abrasive particles on an abrasive article asdescribed herein can define a first portion of a batch of abrasiveparticles, and the features described in the embodiments herein canrepresent features that are present in at least a first portion of abatch of shaped abrasive particles. Moreover, according to anembodiment, control of one or more process parameters as alreadydescribed herein also can control the prevalence of one or more featuresof the shaped abrasive particles of the embodiments herein. Theprovision of one or more features of any shaped abrasive particle of abatch may facilitate alternative or improved deployment of the particlesin an abrasive article and may further facilitate improved performanceor use of the abrasive article. The batch may also include a secondportion of abrasive particles. The second portion of abrasive particlescan include diluent particles.

In accordance with one aspect of the embodiments herein, a fixedabrasive article can include a blend of abrasive particles. The blend ofabrasive particles can include a first type of shaped abrasive particleand a second type of shaped abrasive particle. In particular instances,the first type of shaped abrasive particle can be defined by a firstheight (h1). It will be appreciated that reference to the first heightcan include any height dimension identified in the embodiments herein,including, for example, but not limited to, a median interior height(Mhi) of the first type of shaped abrasive particle. Moreover, thesecond type of shaped abrasive particle can be defined by a secondheight (h2). It will be appreciated that reference to the second heightcan include any height dimension identified in the embodiments herein,including, for example, but not limited to, a median interior height(Mhi) of the second type of shaped abrasive particle.

In accordance with one embodiment, the second type of shaped abrasiveparticle can have a second height (h2) that is less than the firstheight (h1). More particularly, in certain instances, the blend ofabrasive particles can have a height ratio (h2/h1) that can describe thesecond height (h2) of the second type of shaped abrasive particle of theblend divided by the first height (h1) of the first type of shapedabrasive particle of the blend. Certain height ratios of the blend mayimprove performance of the abrasive article. For at least oneembodiment, the height ratio (h2/h1) can be not greater than about 0.98.In other instances, the height ratio (h2/h1) can be not greater thanabout 0.95, such as not greater than about 0.93, not greater than about0.90, not greater than about 0.88, not greater than about 0.85, or evennot greater than about 0.83. Still, in another non-limiting embodiment,the height ratio (h2/h1) can be at least about 0.05, such as at leastabout 0.08, at least about 0.1, at least about 0.12, at least about0.15, at least about 0.18, at least about 0.2, at least about 0.22, atleast about 0.25, at least about 0.28, at least about 0.3, at leastabout 0.32, at least about 0.35, at least about 0.4, at least about0.45, at least about 0.5, at least about 0.55, at least about 0.6, oreven at least about 0.65. It will be appreciated that the height ratio(h2/h1) of the blend, including the first type of shaped abrasiveparticle and the second type of shaped abrasive particle, can be withina range between any of the minimum and maximum values noted above.

In certain instances, the blend of abrasive particles may define aparticular height difference (h1−h2) between the first height and thesecond height that may facilitate improved performance of the fixedabrasive article. As indicated, the height difference may define anumerical value of a difference between the second height (h2)subtracted from the first height (h1). For example, the blend may have aheight difference (h1−h2) of at least about 1 micron. In accordance withanother embodiment, the height difference (h1−h2) can be at least about5 microns. In other instances, the height difference may be greater,such as at least about 10 microns, at least about 15 microns, at leastabout 20 microns, at least about 25 microns, at least about 30 microns,at least about 35 microns, at least about 40 microns, at least about 50microns, at least about 60 microns, at least about 70 microns, or evenat least about 80 microns. Still, in one non-limiting embodiment, theheight difference (h1−h2) may be not greater than about 2 mm, such asnot greater than about 1 mm, not greater than about 800 microns, or evennot greater than about 500 microns. It will be appreciated that theheight difference (h1−h2) may be within a range between any of theminimum and maximum values noted above.

As described herein, the shaped abrasive particles of the embodimentsherein may have a body defined by a length, width, and height. Inaccordance with an embodiment, the first type of shaped abrasiveparticle may have a first length, and a second type of shaped abrasiveparticle may have a second length. Moreover, the blend of abrasiveparticles may have a length ratio (l2/l1) that can describe the secondlength (l2) of the second type of shaped abrasive particle of the blenddivided by the first length (l1) of the first type of shaped abrasiveparticle of the blend. Certain length ratios of the blend may facilitateimproved performance of the abrasive article. Accordingly, in certaininstances, the first type of shaped abrasive particle may have a firstlength that is different than the second length corresponding to thesecond type of shaped abrasive particle. However, it will be appreciatedthat the first length of the first type of shaped abrasive particle canbe substantially the same as the second length of the second type ofshaped abrasive particle.

In at least one embodiment, the length ratio (l2/l1) can be at leastabout 0.05, such as at least about 0.08, at least about 0.1, at leastabout 0.12, at least about 0.15, at least about 0.18, at least about0.2, at least about 0.22, at least about 0.25, at least about 0.28, atleast about 0.3, at least about 0.32, at least about 0.35, at leastabout 0.4, at least about 0.45, at least about 0.5, at least about 0.55,at least about 0.6, at least about 0.65, at least about 0.7, at leastabout 0.75, at least about 0.8, at least about 0.9, or even at leastabout 0.95. Still, in one non-limiting embodiment, the length ratio(l2/l1) may be not greater than about 10, such as, not greater thanabout 8, not greater than about 6, not greater than about 5, not greaterthan about 4, not greater than about 3, not greater than about 2, notgreater than about 1.8, not greater than about 1.5, or even not greaterthan about 1.2. It will be appreciated that the length ratio (l2/l1) maybe within a range between any of the minimum and maximum values notedabove.

Furthermore, the blend of abrasive particles may define a particularlength difference (l1−l2), which can define a difference in the firstlength of the first type of shaped abrasive particle of the blendrelative to the second length of the second type of shaped abrasiveparticle of the blend, and which may facilitate improved performance ofthe abrasive article. For example, in one embodiment, the lengthdifference (l1−l2) may be not greater than about 2 mm, such as notgreater than about 1 mm, not greater than about 800 microns, not greaterthan about 500 microns, not greater than about 300 microns, not greaterthan about 100 microns, or even not greater than about 50 microns.Still, in one non-limiting embodiment, the length difference (l1−l2) maybe at least about 1 micron, such as at least about 5 microns, or even atleast about 10 microns. It will be appreciated that the lengthdifference (l1−l2) may be within a range between any of the minimum andmaximum values noted above.

As noted herein, the first type of shaped abrasive particle may have abody defining a first width (w1). Moreover, the second type of shapedabrasive particle may have a body defining a second width (w2).Furthermore, the blend of abrasive particles may have a width ratio(w2/w1) that can describe the second width (w2) of the second type ofshaped abrasive particle of the blend divided by the first width (w1) ofthe first type of shaped abrasive particle of the blend. Certain widthratios of the blend may facilitate improved performance of the abrasivearticle. Accordingly, in certain instances, the first type of shapedabrasive particle may have a first width that is different than thesecond width corresponding to the second type of shaped abrasiveparticle. However, it will be appreciated that the first width of thefirst type of shaped abrasive particle can be substantially the same asthe second width of the second type of shaped abrasive particle.

In one particular embodiment, the width ratio (w2/w1) may be at leastabout 0.08, such as at least about 0.1, at least about 0.12, at leastabout 0.15, at least about 0.18, at least about 0.2, at least about0.22, at least about 0.25, at least about 0.28, at least about 0.3, atleast about 0.32, at least about 0.35, at least about 0.4, at leastabout 0.45, at least about 0.5, at least about 0.55, at least about 0.6,at least about 0.65, at least about 0.7, at least about 0.75, at leastabout 0.8, at least about 0.9, or even at least about 0.95. Still, inanother non-limiting embodiment, the width ratio (w2/w1) may be notgreater than about 10, such as not greater than about 8, not greaterthan about 6, not greater than about 5, not greater than about 4, notgreater than about 3, not greater than about 2, not greater than about1.8, not greater than about 1.5, or even not greater than about 1.2. Itwill be appreciated that the width ratio (w2/w1) may be within a rangebetween any of the minimum and maximum values noted above.

Moreover, the blend of abrasive particles may have a width difference(w1−w2) that may define a difference in width between the first type ofshaped abrasive particle of the blend and the width of the second typeof shaped abrasive particle of the blend, and which may facilitateimproved performance of the abrasive article. In at least oneembodiment, the width difference (w1−w2) may be not greater than about 2mm, such as not greater than about 1 mm, not greater than about 800microns, not greater than about 500 microns, not greater about 300microns, not greater than about 100 microns, or even not greater thanabout 50 microns. Still, in at least one non-limiting embodiment, thewidth difference (w1−w2) can be at least about 1 micron, such as atleast about 5 microns, or even at least about 10 microns. It will beappreciated that the width difference can be within a range between anyof the minimum and maximum values noted above.

In accordance with another aspect, the blend of abrasive particles caninclude a first type of shaped abrasive particle present in a firstcontent (C1), which may be expressed as a percentage (e.g., a weightpercent) of the first type of shaped abrasive particles as compared tothe total content of particles of the blend. Furthermore, the blend ofabrasive particles may include a second content (C2) of the second typeof shaped abrasive particles, expressed as a percentage (e.g., a weightpercent) of the second type of shaped abrasive particles relative to thetotal weight of the blend. In at least one embodiment, the first contentcan be different than the second content. More particularly, in at leastone embodiment, the first content can be less than the second content.

For example, in certain instances, the blend can be formed such that thefirst content (C1) can be not greater than about 90% of the totalcontent of the blend. In another embodiment, the first content may beless, such as not greater than about 85%, not greater than about 80%,not greater than about 75%, not greater than about 70%, not greater thanabout 65%, not greater than about 60%, not greater than about 55%, notgreater than about 50%, not greater than about 45%, not greater thanabout 40%, not greater than about 35%, not greater than about 30%, notgreater than about 25%, not greater than about 20%, not greater thanabout 15%, not greater than about 10%, or even not greater than about5%. Still, in one non-limiting embodiment, the first content of thefirst type of shaped abrasive particles may be present in at least about1% of the total content of abrasive particles of the blend. In yet otherinstances, the first content (C1) may be at least about 5%, such as atleast about 10%, at least about 15%, at least about 20%, at least about25%, at least about 30%, at least about 35%, at least about 40%, atleast about 45%, at least about 50%, at least about 55%, at least about60%, at least about 65%, at least about 70%, at least about 75%, atleast about 80%, at least about 85%, at least about 90%, or even atleast about 95%. It will be appreciated that the first content (C1) maybe present within a range between any of the minimum and maximumpercentages noted above.

The blend of abrasive particles may include a particular content of thesecond type of shaped abrasive particle. For example, the second content(C2) may be not greater than about 98% of the total content of theblend. In other embodiments, the second content may be not greater thanabout 95%, such as not greater than about 90%, not greater than about85%, not greater than about 80%, not greater than about 75%, not greaterthan about 70%, not greater than about 65%, not greater than about 60%,not greater than about 55%, not greater than about 50%, not greater thanabout 45%, not greater than about 40%, not greater than about 35%, notgreater than about 30%, not greater than about 25%, not greater thanabout 20%, not greater than about 15%, not greater than about 10%, oreven not greater than about 5%. Still, in one non-limiting embodiment,the second content (C2) may be present in an amount of at least about 1%of the total content of the blend. For example, the second content maybe at least about 5%, such as at least about 10%, at least about 15%, atleast about 20%, at least about 25%, at least about 30%, at least about35%, at least about 40%, at least about 45%, at least about 50%, atleast about 55%, at least about 60%, at least about 65%, at least about70%, at least about 75%, at least about 80%, at least about 85%, atleast about 90%, or even at least about 95%. It will be appreciated thatthe second content (C2) can be within a range between any of the minimumand maximum percentages noted above.

In accordance with another embodiment, the blend of abrasive particlesmay have a blend ratio (C1/C2) that may define a ratio between the firstcontent (C1) and the second content (C2). For example, in oneembodiment, the blend ratio (C1/C2) may be not greater than about 10. Inyet another embodiment, the blend ratio (C1/C2) may be not greater thanabout 8, such as not greater than about 6, not greater than about 5, notgreater than about 4, not greater than about 3, not greater than about2, not greater than about 1.8, not greater than about 1.5, not greaterthan about 1.2, not greater than about 1, not greater than about 0.9,not greater than about 0.8, not greater than about 0.7, not greater thanabout 0.6, not greater than about 0.5, not greater than about 0.4, notgreater than about 0.3, or even not greater than about 0.2. Still, inanother non-limiting embodiment, the blend ratio (C1/C2) may be at leastabout 0.1, such as at least about 0.15, at least about 0.2, at leastabout 0.22, at least about 0.25, at least about 0.28, at least about0.3, at least about 0.32, at least about 0.3, at least about 0.4, atleast about 0.45, at least about 0.5, at least about 0.55, at leastabout 0.6, at least about 0.65, at least about 0.7, at least about 0.75,at least about 0.8, at least about 0.9, at least about 0.95, at leastabout 1, at least about 1.5, at least about 2, at least about 3, atleast about 4, or even at least about 5. It will be appreciated that theblend ratio (C1/C2) may be within a range between any of the minimum andmaximum values noted above.

In at least one embodiment, the blend of abrasive particles can includea majority content of shaped abrasive particles. That is, the blend canbe formed primarily of shaped abrasive particles, including, but notlimited to, a first type of shaped abrasive particle and a second typeof shaped abrasive particle. In at least one particular embodiment, theblend of abrasive particles can consist essentially of the first type ofshaped abrasive particle and the second type of shaped abrasiveparticle. However, in other non-limiting embodiments, the blend mayinclude other types of abrasive particles. For example, the blend mayinclude a third type of abrasive particle that may include aconventional abrasive particle or a shaped abrasive particle. The thirdtype of abrasive particle may include a diluent type of abrasiveparticle having an irregular shape, which may be achieved throughconventional crushing and comminution techniques.

For at least one aspect, a fixed abrasive article according to anembodiment can include a blend of abrasive particles including a firsttype of shaped abrasive particle and a second type of shaped abrasiveparticle, wherein the fixed abrasive article comprises a stainless steellifespan of at least about 11 in³. The stainless steel lifespan of afixed abrasive article can be determined according to the standardstainless steel grinding characterization test as defined herein. In oneembodiment, the fixed abrasive article can have a stainless steellifespan of at least about 11.5 in³, such as at least about 12 in³.Still, in another non-limiting embodiment, the fixed abrasive articlecan have a stainless steel lifespan of not greater than about 25 in³,such as not greater than about 20 in³. It will be appreciated that afixed abrasive article according to an embodiment can have a stainlesssteel lifespan within a range between and including any of the minimumand maximum values noted above.

According to another embodiment, the blend of abrasive particles caninclude a plurality of shaped abrasive particles, and each of the shapedabrasive particles of the plurality may be arranged in a controlledorientation relative to a backing. Suitable exemplary controlledorientations can include at least one of a predetermined rotationalorientation, a predetermined lateral orientation, and a predeterminedlongitudinal orientation. In at least one embodiment, the plurality ofshaped abrasive particles having a controlled orientation can include atleast a portion of the first type of shaped abrasive particles of theblend, at least a portion of the second type of shaped abrasiveparticles of the blend, and a combination thereof. More particularly,the plurality of shaped abrasive particles having a controlledorientation can include all of the first type of shaped abrasiveparticles. In still another embodiment, the plurality of shaped abrasiveparticles arranged in a controlled orientation relative to the backingmay include all of the second type of shaped abrasive particles withinthe blend of abrasive particles.

FIG. 7 includes a top view illustration of a portion of a coatedabrasive article, including shaped abrasive particles having controlledorientation. As illustrated, the coated abrasive article 700 includes abacking 701 that can be defined by a longitudinal axis 780 that extendsalong and defines a length of the backing 701 and a lateral axis 781that extends along and defines a width of the backing 701. In accordancewith an embodiment, a shaped abrasive particle 702 can be located in afirst, predetermined position 712 defined by a particular first lateralposition relative to the lateral axis of 781 of the backing 701 and afirst longitudinal position relative to the longitudinal axis 780 of thebacking 701. Furthermore, a shaped abrasive particle 703 may have asecond, predetermined position 713 defined by a second lateral positionrelative to the lateral axis 781 of the backing 701, and a firstlongitudinal position relative to the longitudinal axis 780 of thebacking 701 that is substantially the same as the first longitudinalposition of the shaped abrasive particle 702. Notably, the shapedabrasive particles 702 and 703 may be spaced apart from each other by alateral space 721, defined as a smallest distance between the twoadjacent shaped abrasive particles 702 and 703 as measured along alateral plane 784 parallel to the lateral axis 781 of the backing 701.In accordance with an embodiment, the lateral space 721 can be greaterthan zero, such that some distance exists between the shaped abrasiveparticles 702 and 703. However, while not illustrated, it will beappreciated that the lateral space 721 can be zero, allowing for contactand even overlap between portions of adjacent shaped abrasive particles.

As further illustrated, the coated abrasive article 700 can include ashaped abrasive particle 704 located at a third, predetermined position714 defined by a second longitudinal position relative to thelongitudinal axis 780 of the backing 701 and also defined by a thirdlateral position relative to a lateral plane 785 parallel to the lateralaxis 781 of the backing 701 and spaced apart from the lateral axis 784.Further, as illustrated, a longitudinal space 723 may exist between theshaped abrasive particles 702 and 704, which can be defined as asmallest distance between the two adjacent shaped abrasive particles 702and 704 as measured in a direction parallel to the longitudinal axis780. In accordance with an embodiment, the longitudinal space 723 can begreater than zero. Still, while not illustrated, it will be appreciatedthat the longitudinal space 723 can be zero, such that the adjacentshaped abrasive particles are touching or even overlapping each other.

FIG. 8A includes a top view illustration of a portion of an abrasivearticle, including shaped abrasive particles in accordance with anembodiment. As illustrated, the abrasive article 800 can include ashaped abrasive particle 802 overlying a backing 801 in a first positionhaving a first rotational orientation relative to a lateral axis 781defining the width of the backing 801. In particular, the shapedabrasive particle 802 can have a predetermined rotational orientationdefined by a first rotational angle between a lateral plane 884 parallelto the lateral axis 781 and a dimension of the shaped abrasive particle802. Notably, reference herein to a dimension of the shaped abrasiveparticle 802 can include reference to a bisecting axis 831 of the shapedabrasive particle 802, such bisecting axis 831 extending through acenter point 821 of the shaped abrasive particle 802 along a surface(e.g., a side or an edge) connected to (directly or indirectly) thebacking 801. Accordingly, in the context of a shaped abrasive particlepositioned in a side orientation (see, e.g., FIG. 6), the bisecting axis831 can extend through a center point 821 and in the direction of thewidth (w) of a side 833 closest to the surface of the backing 801.

In certain embodiments, the predetermined rotational orientation of theshaped abrasive particle 802 can be defined by a predeterminedrotational angle 841 that defines the smallest angle between thebisecting axis 831 and the lateral plane 884, both of which extendthrough the center point 821 as viewed from the top down in FIG. 8A. Inaccordance with an embodiment, the predetermined rotational angle 841,and thus the predetermined rotational orientation, can be 0°. In otherembodiments, the predetermined rotational angle defining thepredetermined rotational orientation can be greater, such as at leastabout 2°, at least about 5°, at least about 10°, at least about 15°, atleast about 20°, at least about 25°, at least about 30°, at least about35°, at least about 40°, at least about 45°, at least about 50°, atleast about 55°, at least about 60°, at least about 70°, at least about80°, or even at least about 85°. Still, the predetermined rotationalorientation as defined by the rotational angle 841 may be not greaterthan about 90°, such as not greater than about 85°, not greater thanabout 80°, not greater than about 75°, not greater than about 70°, notgreater than about 65°, not greater than about 60°, such as not greaterthan about 55°, not greater than about 50°, not greater than about 45°,not greater than about 40°, not greater than about 35°, not greater thanabout 30°, not greater than about 25°, not greater than about 20°, suchas not greater than about 15°, not greater than about 10°, or even notgreater than about 5°. It will be appreciated that the predeterminedrotational orientation can be within a range between any of the aboveminimum and maximum angles.

FIG. 8B includes a perspective view illustration of a portion of theabrasive article 800, including the shaped abrasive particle 802 inaccordance with an embodiment. As illustrated, the abrasive article 800can include the shaped abrasive particle 802 overlying the backing 801in a first position 812 such that the shaped abrasive particle 802includes a first rotational orientation relative to the lateral axis 781defining the width of the backing 801. Certain aspects of thepredetermined orientation of a shaped abrasive particle may be describedby reference to a x, y, z three-dimensional axis as illustrated. Forexample, the predetermined longitudinal orientation of the shapedabrasive particle 802 may be described by reference to the position ofthe shaped abrasive particle 802 relative to the y-axis, which extendsparallel to the longitudinal axis 780 of the backing 801. Moreover, thepredetermined lateral orientation of the shaped abrasive particle 802may be described by reference to the position of the shaped abrasiveparticle on the x-axis, which extends parallel to the lateral axis 781of the backing 801. Furthermore, the predetermined rotationalorientation of the shaped abrasive particle 802 may be defined withreference to a bisecting axis 831 that extends through the center point821 of the side 833 of the shaped abrasive particle 802. Notably, theside 833 of the shaped abrasive particle 802 may be connected eitherdirectly or indirectly to the backing 801. In a particular embodiment,the bisecting axis 831 may form an angle with any suitable referenceaxis, including, for example, the x-axis that extends parallel to thelateral axis 781. The predetermined rotational orientation of the shapedabrasive particle 802 may be described as a rotational angle formedbetween the x-axis and the bisecting axis 831, which rotational angle isdepicted in FIG. 8B as angle 841. Notably, the controlled placement of aplurality of shaped abrasive particles on the backing of the abrasivearticle, which placement facilitates control of the predeterminedorientation characteristics described herein, is a highly involvedprocess that has not previously been contemplated or deployed in theindustry.

FIG. 9 includes a perspective view illustration of a portion of anabrasive article, including shaped abrasive particles havingpredetermined orientation characteristics relative to a grindingdirection in accordance with an embodiment. In one embodiment, theabrasive article 900 can include a shaped abrasive particle 902 having apredetermined orientation relative to another shaped abrasive particle903 and/or relative to a grinding direction 985. The grinding direction985 may be an intended direction of movement of the abrasive articlerelative to a workpiece in a material removal operation. In particularinstances, the grinding direction 985 may be defined relative to thedimensions of the backing 901. For example, in one embodiment, thegrinding direction 985 may be substantially perpendicular to the lateralaxis 981 of the backing and substantially parallel to the longitudinalaxis 980 of the backing 901. The predetermined orientationcharacteristics of the shaped abrasive particle 902 may define aninitial contact surface of the shaped abrasive particle 902 with aworkpiece. For example, the shaped abrasive particle 902 can includemajor surfaces 963 and 964 and side surfaces 965 and 966, each of whichcan extend between the major surfaces 963 and 964. The predeterminedorientation characteristics of the shaped abrasive particle 902 canposition the particle 902 such that the major surface 963 is configuredto make initial contact with a workpiece before the other surfaces ofthe shaped abrasive particle 902 during a material removal operation.Such an orientation may be considered a major surface orientationrelative to the grinding direction 985. More particularly, the shapedabrasive particle 902 can have a bisecting axis 931 having a particularorientation relative to the grinding direction 985. For example, asillustrated, the vector of the grinding direction 985 and the bisectingaxis 931 are substantially perpendicular to each other. It will beappreciated that, just as any range of predetermined rotationalorientations relative to the backing are contemplated for a shapedabrasive particle, any range of orientations of the shaped abrasiveparticles relative to the grinding direction 985 are contemplated andcan be utilized.

The shaped abrasive particle 903 can have one or more differentpredetermined orientation characteristics as compared to the shapedabrasive particle 902 and the grinding direction 985. As illustrated,the shaped abrasive particle 903 can include major surfaces 991 and 992,each of which can be joined by side surfaces 971 and 972. Moreover, asillustrated, the shaped abrasive particle 903 can have a bisecting axis973 forming a particular angle relative to the vector of the grindingdirection 985. As illustrated, the bisecting axis 973 of the shapedabrasive particle 903 can have a substantially parallel orientation withthe grinding direction 985 such that the angle between the bisectingaxis 973 and the grinding direction 985 is essentially 0 degrees.Accordingly, the predetermined orientation characteristics of the shapedabrasive particle 903 facilitate initial contact of the side surface 972with a workpiece before any of the other surfaces of the shaped abrasiveparticle 903. Such an orientation of the shaped abrasive particle 903may be considered a side surface orientation relative to the grindingdirection 985.

Still, in one non-limiting embodiment, it will be appreciated that anabrasive article can include one or more groups of shaped abrasiveparticles that can be arranged in one or more predetermineddistributions relative to the backing, a grinding direction, and/or eachother. For example, one or more groups of shaped abrasive particles, asdescribed herein, can have a predetermined orientation relative to agrinding direction. Moreover, the abrasive articles herein can have oneor more groups of shaped abrasive particles, each of the groups having adifferent predetermined orientation relative to a grinding direction.Utilization of groups of shaped abrasive particles having differentpredetermined orientations relative to a grinding direction canfacilitate improved performance of the abrasive article.

FIG. 10 includes a top view illustration of a portion of an abrasivearticle in accordance with an embodiment. In particular, the abrasivearticle 1000 can include a first group 1001 including a plurality ofshaped abrasive particles. As illustrated, the shaped abrasive particlescan be arranged relative to each other on the backing 101 to define apredetermined distribution. More particularly, the predetermineddistribution can be in the form of a pattern 1023 as viewed top-down,and more particularly defining a triangular-shaped two-dimensionalarray. As further illustrated, the first group 1001 can be arranged onthe abrasive article 1000 defining a predetermined macro-shape 1031overlying the backing 101. In accordance with an embodiment, themacro-shape 1031 can have a particular two-dimensional shape as viewedtop-down. Some exemplary two-dimensional shapes can include polygons,ellipsoids, numerals, Greek alphabet characters, Latin alphabetcharacters, Russian alphabet characters, Arabic alphabet characters,Kanji characters, complex shapes, irregular shapes, designs, anycombination thereof. In particular instances, the formation of a grouphaving a particular macro-shape may facilitate improved performance ofthe abrasive article.

As further illustrated, the abrasive article 1000 can include a group1004 including a plurality of shaped abrasive particles, which can bearranged on the surface of the backing 101 relative to each other todefine a predetermined distribution. Notably, the predetermineddistribution can include an arrangement of the plurality of the shapedabrasive particles that define a pattern 1024, and more particularly, agenerally quadrilateral pattern. As illustrated, the group 1004 candefine a macro-shape 1034 on the surface of the abrasive article 1000.In one embodiment, the macro-shape 1034 of the group 1004 can have atwo-dimensional shape as viewed top-down, including, for example, apolygonal shape, and more particularly, a generally quadrilateral(diamond) shape as viewed top down on the surface of the abrasivearticle 1000. In the illustrated embodiment of FIG. 10, the group 1001can have a macro-shape 1031 that is substantially the same as themacro-shape 1034 of the group 1004. However, it will be appreciated thatin other embodiments, various different groups can be used on thesurface of the abrasive article, and more particularly, wherein each ofthe different groups has a different macro-shape relative to each other.

As further illustrated, the abrasive article can include groups 1001,1002, 1003, and 1004 which can be separated by channel regions 1021 and1022 extending between the groups 1001-1004. In particular instances,the channel regions 1021 and 1022 can be substantially free of shapedabrasive particles. Moreover, the channel regions 1021 and 1022 may beconfigured to move liquid between the groups 1001-1004 and furtherimprove swarf removal and grinding performance of the abrasive article.Furthermore, in a certain embodiment, the abrasive article 1000 caninclude channel regions 1021 and 1022 extending between groups1001-1004, wherein the channel regions 1021 and 1022 can be patterned onthe surface of the abrasive article 1000. In particular instances, thechannel regions 1021 and 1022 can represent a regular and repeatingarray of features extending along a surface of the abrasive article.

The fixed abrasive articles of the embodiments herein can be utilized invarious material removal operations. For example, fixed abrasivearticles herein can be used in methods of removing material from aworkpiece by moving the fixed abrasive article relative to theworkpiece. The relative movement between the fixed abrasive and theworkpiece can facilitate removal of the material from the surface of theworkpiece. Various workpieces can be modified using the fixed abrasivearticles of the embodiments herein, including but not limited to,workpieces comprising inorganic materials, organic materials, and acombination thereof. In a particular embodiment, the workpiece mayinclude a metal, such as a metal alloy. In one particular instance, theworkpiece can consist essentially of a metal or metal alloy, such asstainless steel.

Item 1. A fixed abrasive article comprising:

a blend of abrasive particles comprising:

a first type of shaped abrasive particle comprising a first height (h1);

a second type of shaped abrasive particle comprising a second height(h2) less than the first height.

Item 2. The fixed abrasive article of item 1, further comprising aheight ratio (h2/h1) of not greater than about 0.98, wherein the heightratio (h2/h1) is not greater than about 0.95 or not greater than about0.93 or not greater than about 0.90 or not greater than about 0.88 ornot greater than about 0.85 or not greater than about 0.83.

Item 3. The fixed abrasive article of item 2, wherein the height ratio(h2/h1) is at least about 0.05 or at least about 0.08 or at least about0.1 or at least about 0.12 or at least about 0.15 or at least about 0.18or at least about 0.2 or at least about 0.22 or at least about 0.25 orat least about 0.28 or at least about 0.3 or at least about 0.32 or atleast about 0.35 or at least about 0.4 or at least about 0.45 or atleast about 0.5 or at least about 0.55 or at least about 0.6 or at leastabout 0.65.

Item 4. The fixed abrasive article of item 1, further comprising aheight difference (h1−h2) of at least about 1 micron.

Item 5. The fixed abrasive article of item 4, wherein the heightdifference (h1−h2) is at least about 5 microns or at least about 10microns or at least about 15 microns or at least about 20 microns or atleast about 25 microns or at least about 30 microns or at least about 35microns or at least about 40 microns or at least about 50 microns or atleast about 60 microns or at least about 70 microns or at least about 80microns.

Item 6. The fixed abrasive article of item 4, wherein the heightdifference (h1−h2) is not greater than about 2 mm or not greater thanabout 1 mm or not greater than about 800 microns or not greater thanabout 500 microns.

Item 7. The fixed abrasive article of item 1, wherein the first type ofshaped abrasive particle comprises a first length (l1), and the secondtype of shaped abrasive particle comprises a second length (l2), andfurther comprising a length ratio (l1/l2) of at least about 0.05.

Item 8. The fixed abrasive article of item 7, wherein the length ratio(l1/l2) is at least about 0.08 or at least about 0.1 or at least about0.12 or at least about 0.15 or at least about 0.18 or at least about 0.2or at least about 0.22 or at least about 0.25 or at least about 0.28 orat least about 0.3 or at least about 0.32 or at least about 0.35 or atleast about 0.4 or at least about 0.45 or at least about 0.5 or at leastabout 0.55 or at least about 0.6 or at least about 0.65 or at leastabout 0.7 or at least about 0.75 or at least about 0.8 or at least about0.9 or at least about 0.95.

Item 9. The fixed abrasive article of item 7, wherein the length ratio(l1/l2) is not greater than about 10 or not greater than about 8 or notgreater than about 6 or not greater than about 5 or not greater thanabout 4 or not greater than about 3 or not greater than about 2 or notgreater than about 1.8 or not greater than about 1.5 or not greater thanabout 1.2.

Item 10. The fixed abrasive article of item 7, further comprising alength difference (L1−l2) of not greater than about 2 mm or not greaterthan about 1 mm or not greater than about 800 microns or not greaterthan about 500 microns or not greater than about 300 microns or notgreater than about 100 microns or not greater than about 50 microns.

Item 11. The fixed abrasive article of item 10, wherein the lengthdifference (L1−l2) can be at least about 1 micron or at least about 5microns or at least about 10 microns.

Item 12. The fixed abrasive article of item 1, wherein the first type ofshaped abrasive particle comprises a first width (w1), and the secondtype of shaped abrasive particle comprises a second width (w2), andfurther comprising a width ratio (w2/w1) of at least about 0.05.

Item 13. The fixed abrasive article of item 12, wherein the width ratio(w2/w1) is at least about 0.08 or at least about 0.1 or at least about0.12 or at least about 0.15 or at least about 0.18 or at least about 0.2or at least about 0.22 or at least about 0.25 or at least about 0.28 orat least about 0.3 or at least about 0.32 or at least about 0.35 or atleast about 0.4 or at least about 0.45 or at least about 0.5 or at leastabout 0.55 or at least about 0.6 or at least about 0.65 or at leastabout 0.7 or at least about 0.75 or at least about 0.8 or at least about0.9 or at least about 0.95.

Item 14. The fixed abrasive article of item 12, wherein the width ratio(w2/w1) is not greater than about 10 or not greater than about 8 or notgreater than about 6 or not greater than about 5 or not greater thanabout 4 or not greater than about 3 or not greater than about 2 or notgreater than about 1.8 or not greater than about 1.5 or not greater thanabout 1.2.

Item 15. The fixed abrasive article of item 12, further comprising awidth difference (w1−w2) of not greater than about 2 mm or not greaterthan about 1 mm or not greater than about 800 microns or not greaterthan about 500 microns or not greater than about 300 microns or notgreater than about 100 microns or not greater than about 50 microns.

Item 16. The fixed abrasive article of item 15, wherein the widthdifference (w1−w2) can be at least about 1 micron or at least about 5microns or at least about 10 microns.

Item 17. The fixed abrasive article of item 1, wherein the first contentis less than the second content.

Item 18. The fixed abrasive article of item 1, wherein the first contentis not greater than about 90% of the total content of the blend or notgreater than about 85% or not greater than about 80% or not greater thanabout 75% or not greater than about 70% or not greater than about 65% ornot greater than about 60% or not greater than about 55% or not greaterthan about 50% or not greater than about 45% or not greater than about40% or not greater than about 35% or not greater than about 30% or notgreater than about 25% or not greater than about 20% or not greater thanabout 15% or not greater than about 10% or not greater than about 5%.

Item 19. The fixed abrasive article of item 1, wherein the first contentis at least about 1% of the total content of the blend or at least about5% or at least about 10% or at least about 15% or at least about 20% orat least about 25% or at least about 30% or at least about 35% or atleast about 40% or at least about 45% or at least about 50% or at leastabout 55% or at least about 60% or at least about 65% or at least about70% or at least about 75% or at least about 80% or at least about 85% orat least about 90% or at least about 95%.

Item 20. The fixed abrasive article of item 1, wherein the secondcontent is not greater than about 98% of the total content of the blendor not greater than about 95% or not greater than about 90% or notgreater than about 85% or not greater than about 80% or not greater thanabout 75% or not greater than about 70% or not greater than about 65% ornot greater than about 60% or not greater than about 55% or not greaterthan about 50% or not greater than about 45% or not greater than about40% or not greater than about 35% or not greater than about 30% or notgreater than about 25% or not greater than about 20% or not greater thanabout 15% or not greater than about 10% or not greater than about 5%.

Item 21. The fixed abrasive article of item 1, wherein the secondcontent is at least about 1% of the total content of the blend or atleast about 5% or at least about 10% or at least about 15% or at leastabout 20% or at least about 25% or at least about 30% or at least about35% or at least about 40% or at least about 45% or at least about 50% orat least about 55% or at least about 60% or at least about 65% or atleast about 70% or at least about 75% or at least about 80% or at leastabout 85% or at least about 90% or at least about 95%.

Item 22. The fixed abrasive article of item 1, wherein the blend ofabrasive particles comprises a first content (C1) of the first type ofshaped abrasive particle, and a second content (C2) of the second typeof shaped abrasive particle, and further comprising a blend ratio(C1/C2) of not greater than about 10.

Item 23. The fixed abrasive article of item 22, wherein the blend ratio(C1/C2) is not greater than about 8 or not greater than about 6 or notgreater than about 5 or not greater than about 4 or not greater thanabout 3 or not greater than about 2 or not greater than about 1.8 or notgreater than about 1.5 or not greater than about 1.2 or not greater thanabout 1 or not greater than about 0.9 or not greater than about 0.8 ornot greater than about 0.7 or not greater than about 0.6 or not greaterthan about 0.5 or not greater than about 0.4 or not greater than about0.3 or not greater than about 0.2.

Item 24. The fixed abrasive article of item 22, wherein the blend ratio(C1/C2) is at least about 0.1 or at least about 0.15 or at least about0.2 or at least about 0.22 or at least about 0.25 or at least about 0.28or at least about 0.3 or at least about 0.32 or at least about 0.35 orat least about 0.4 or at least about 0.45 or at least about 0.5 or atleast about 0.55 or at least about 0.6 or at least about 0.65 or atleast about 0.7 or at least about 0.75 or at least about 0.8 or at leastabout 0.9 or at least about 0.95 or at least about 1 or at least about1.5 or at least about 2 or at least about 3 or at least about 4 or atleast about 5.

Item 25. The fixed abrasive article of item 1, wherein the blend ofabrasive particles includes a majority content of shaped abrasiveparticles.

Item 26. The fixed abrasive article of item 1, wherein the blend ofabrasive particles consists essentially of the first type of shapedabrasive particle and the second type of shaped abrasive particle.

Item 27. The fixed abrasive article of item 1, wherein the blend furthercomprises a third type of abrasive particle, wherein the third type ofabrasive particle comprises a shaped abrasive particle, wherein thethird type of abrasive particle comprises a diluent type of abrasiveparticle, wherein the diluent type of abrasive particle comprises anirregular shape.

Item 28. The fixed abrasive article of item 1, wherein the fixedabrasive article is selected from the group consisting of a bondedabrasive article, a coated abrasive article, and a combination thereof.

Item 29. The fixed abrasive article of item 1, wherein the fixedabrasive article comprises a substrate, wherein the substrate comprisesa backing, wherein the backing comprises a woven material, wherein thebacking comprises a non-woven material, wherein the backing comprises anorganic material, wherein the backing comprises a polymer, wherein thebacking comprises a material selected from the group consisting ofcloth, paper, film, fabric, fleeced fabric, vulcanized fiber, wovenmaterial, non-woven material, webbing, polymer, resin, phenolic resin,phenolic-latex resin, epoxy resin, polyester resin, urea-formaldehyderesin, polyester, polyurethane, polypropylene, polyimides, and acombination thereof.

Item 30. The fixed abrasive article of item 29, wherein the backingcomprises an additive selected from the group consisting of catalysts,coupling agents, curants, anti-static agents, suspending agents,anti-loading agents, lubricants, wetting agents, dyes, fillers,viscosity modifiers, dispersants, defoamers, and grinding agents.

Item 31. The fixed abrasive article of item 29, further comprising anadhesive layer overlying the backing, wherein the adhesive layercomprises a make coat, wherein the make coat overlies the backing,wherein the make coat is bonded directly to a portion of the backing,wherein the make coat comprises an organic material, wherein the makecoat comprises a polymeric material, wherein the make coat comprises amaterial selected from the group consisting of polyesters, epoxy resins,polyurethanes, polyamides, polyacrylates, polymethacrylates, poly vinylchlorides, polyethylene, polysiloxane, silicones, cellulose acetates,nitrocellulose, natural rubber, starch, shellac, and a combinationthereof.

Item 32. The fixed abrasive article of item 31, wherein the adhesivelayer comprises a size coat, wherein the size coat overlies a portion ofthe plurality of shaped abrasive particles, wherein the size coatoverlies a make coat, wherein the size coat is bonded directly to aportion of the plurality of shaped abrasive particles, wherein the sizecoat comprises an organic material, wherein the size coat comprises apolymeric material, wherein the size coat comprises a material selectedfrom the group consisting of polyesters, epoxy resins, polyurethanes,polyamides, polyacrylates, polymethacrylates, polyvinyl chlorides,polyethylene, polysiloxane, silicones, cellulose acetates,nitrocellulose, natural rubber, starch, shellac, and a combinationthereof.

Item 33. The fixed abrasive article of item 1, wherein the blend ofabrasive particles comprises a plurality of shaped abrasive particles,and wherein each shaped abrasive particle of the plurality of shapedabrasive particles is arranged in a controlled orientation relative to abacking, the controlled orientation including at least one of apredetermined rotational orientation, a predetermined lateralorientation, and a predetermined longitudinal orientation.

Item 34. The fixed abrasive article of item 33, wherein the plurality ofshaped abrasive particles includes at least a portion of the first typeof shaped abrasive particles, wherein the plurality of shaped abrasiveparticles includes all of the first type of shaped abrasive particles.

Item 35. The fixed abrasive article of item 33, wherein the plurality ofshaped abrasive particles includes at least a portion of the second typeof shaped abrasive particles, wherein the plurality of shaped abrasiveparticles includes all of the second type of shaped abrasive particles.

Item 36. The fixed abrasive article of item 33, wherein a majority ofthe first type of abrasive particles are coupled to the backing in aside orientation, wherein at least about 55% of the shaped abrasiveparticles of the plurality of shaped abrasive particles are coupled tothe backing in a side orientation or at least about 60% or at leastabout 65% or at least about 70% or at least about 75% or at least about77% or at least about 80%, and not greater than about 99% or not greaterthan about 95% or not greater than about 90% or not greater than about85%.

Item 37. The fixed abrasive article of item 33, wherein a majority ofthe second type of abrasive particles are coupled to the backing in aside orientation, wherein at least about 55% of the shaped abrasiveparticles of the plurality of shaped abrasive particles are coupled tothe backing in a side orientation or at least about 60% or at leastabout 65% or at least about 70% or at least about 75% or at least about77% or at least about 80%, and not greater than about 99% or not greaterthan about 95% or not greater than about 90% or not greater than about85%.

Item 38. The fixed abrasive article of item 1, wherein the fixedabrasive article comprises a coated abrasive article having an open coatof the blend of shaped abrasive particles on a backing, wherein the opencoat comprises a coating density of not greater than about 70particles/cm² or not greater than about 65 particles/cm² or not greaterthan about 60 particles/cm² or not greater than about 55 particles/cm²or not greater than about 50 particles/cm², at least about 5particles/cm² or at least about 10 particles/cm².

Item 39. The fixed abrasive article of item 1, wherein the fixedabrasive article comprises a coated abrasive article having a closedcoat of the blend of shaped abrasive particles on a backing, wherein theclosed coat comprises a coating density of at least about 75particles/cm² or at least about 80 particles/cm² or at least about 85particles/cm² or at least about 90 particles/cm² or at least about 100particles/cm².

Item 40. The fixed abrasive article of item 1, wherein the first type ofshaped abrasive particle comprises a body having a length (l), a width(w), and a height (hi), wherein the width≥length, the length≥height, andthe width≥height.

Item 41. The fixed abrasive article of item 40, wherein the height (h)is at least about 20% of the width (w) or at least about 25% or at leastabout 30% or at least about 33%, and not greater than about 80% or notgreater than about 76% or not greater than about 73% or not greater thanabout 70% or not greater than about 68% of the width or not greater thanabout 56% of the width or not greater than about 48% of the width or notgreater than about 40% of the width.

Item 42. The fixed abrasive article of item 40, wherein the height (h)is at least about 400 microns or at least about 450 microns or at leastabout 475 microns or at least about 500 microns, and not greater thanabout 3 mm or not greater than about 2 mm or not greater than about 1.5mm or not greater than about 1 mm or not greater than about 800 microns.

Item 43. The fixed abrasive article of item 40, wherein the width is atleast about 600 microns or at least about 700 microns or at least about800 microns or at least about 900 microns, and not greater than about 4mm or not greater than about 3 mm or not greater than about 2.5 mm ornot greater than about 2 mm.

Item 44. The fixed abrasive article of item 40, wherein the bodycomprises a percent flashing of at least about 1%, such as at leastabout 2% or at least about 3% or at least about 5% or at least about 8%or at least about 10% or at least about 12% or at least about 15% or atleast about 18% or at least about 20%, and not greater than about 40% ornot greater than about 35% or not greater than about 30% or not greaterthan about 25% or not greater than about 20% or not greater than about18% or not greater than about 15% or not greater than about 12% or notgreater than about 10% or not greater than about 8% or not greater thanabout 6% or not greater than about 4%.

Item 45. The fixed abrasive article of item 40, wherein the bodycomprises a dishing value (d) of not greater than about 2 or not greaterthan about 1.9 or not greater than about 1.8 or not greater than about1.7 or not greater than about 1.6 or not greater than about 1.5 or notgreater than about 1.2, and at least about 0.9 or at least about 1.0.

Item 46. The fixed abrasive article of item 40, wherein the bodycomprises a primary aspect ratio of width:length of at least about 1:1and not greater than about 10:1.

Item 47. The fixed abrasive article of item 40, wherein the bodycomprises a secondary aspect ratio defined by a ratio of width:heightwithin a range between about 5:1 and about 1:1.

Item 48. The fixed abrasive article of item 40, wherein the bodycomprises a tertiary aspect ratio defined by a ratio of length:heightwithin a range between about 6:1 and about 1:1.

Item 49. The fixed abrasive article of item 40, wherein the bodycomprises a two-dimensional polygonal shape as viewed in a plane definedby a length and width, wherein the body comprises a shape selected fromthe group consisting of triangular, quadrilateral, rectangular,trapezoidal, pentagonal, hexagonal, heptagonal, octagonal, and acombination thereof, wherein the body comprises a two-dimensional shapeas viewed in a plane defined by a length and a width of the bodyselected from the group consisting of ellipsoids, Greek alphabetcharacters, Latin alphabet characters, Russian alphabet characters,complex polygonal shapes, irregular shapes, and a combination thereof.

Item 50. The fixed abrasive article of item 40, wherein the bodycomprises a two-dimensional triangular shape as viewed in a planedefined by a length and width.

Item 51. The fixed abrasive article of item 40, wherein the body isessentially free of a binder, wherein the body is essentially free of anorganic material.

Item 52. The fixed abrasive article of item 40, wherein the bodycomprises a polycrystalline material, wherein the polycrystallinematerial comprises grains, wherein the grains are selected from thegroup of materials consisting of nitrides, oxides, carbides, borides,oxynitrides, diamond, and a combination thereof, wherein the grainscomprise an oxide selected from the group of oxides consisting ofaluminum oxide, zirconium oxide, titanium oxide, yttrium oxide, chromiumoxide, strontium oxide, silicon oxide, and a combination thereof,wherein the grains comprise alumina, wherein the grains consistessentially of alumina.

Item 53. The fixed abrasive article of item 40, wherein the bodyconsists essentially of alumina.

Item 54. The fixed abrasive article of item 40, wherein the body isformed from a seeded sol gel.

Item 55. The fixed abrasive article of item 40, wherein the bodycomprises a polycrystalline material having an average grain size notgreater than about 1 micron.

Item 56. The fixed abrasive article of item 40, wherein the body is acomposite comprising at least about two different types of grains.

Item 57. The fixed abrasive article of item 40, wherein the bodycomprises an additive, wherein the additive comprises an oxide, whereinthe additive comprises a metal element, wherein the additive comprises arare-earth element.

Item 58. The fixed abrasive article of item 57, wherein the additivecomprises a dopant material, wherein the dopant material includes anelement selected from the group consisting of an alkali element, analkaline earth element, a rare earth element, a transition metalelement, and a combination thereof, wherein the dopant materialcomprises an element selected from the group consisting of hafnium,zirconium, niobium, tantalum, molybdenum, vanadium, lithium, sodium,potassium, magnesium, calcium, strontium, barium, scandium, yttrium,lanthanum, cesium, praseodymium, chromium, cobalt, iron, germanium,manganese, nickel, titanium, zinc, and a combination thereof.

Item 59. The fixed abrasive article of item 1, wherein the first type ofshaped abrasive particle comprises a body having a first major surface,a second major surface, and at least one side surface extending betweenthe first major surface and the second major surface.

Item 60. The fixed abrasive article of item 59, wherein the first majorsurface defines an area different than the second major surface, whereinthe first major surface defines an area greater than an area defined bythe second major surface, wherein the first major surface defines anarea less than an area defined by the second major surface.

Item 61. The fixed abrasive article of item 1, wherein the first type ofshaped abrasive particle comprises a first abrasive characteristicselected from the group consisting of two-dimensional shape, averageparticle size, particle color, hardness, friability, toughness, density,specific surface area, and a combination thereof.

Item 62. The fixed abrasive article of item 61, wherein the second typeof shaped abrasive particle comprises a second abrasive characteristicselected from the group consisting of two-dimensional shape, averageparticle size, particle color, hardness, friability, toughness, density,specific surface area, and a combination thereof.

Item 63. The fixed abrasive article of item 62, wherein at least onefirst abrasive characteristic and second abrasive characteristic areessentially the same compared to each other, wherein at least two firstabrasive characteristics and two second abrasive characteristics areessentially the same compared to each other.

Item 64. The fixed abrasive article of item 62, wherein at least onefirst abrasive characteristic and one second abrasive characteristic aredifferent compared to each other, wherein at least two first abrasivecharacteristics and two second abrasive characteristics are differentcompared to each other.

Item 65. The fixed abrasive article of item 1, wherein the second typeof shaped abrasive particle comprises a body having a length (l), awidth (w), and a height (hi), wherein the width>length, thelength>height, and the width>height.

Item 66. The fixed abrasive article of item 65, wherein the height (h)is at least about 20% of the width (w) or at least about 25% or at leastabout 30% or at least about 33%, and not greater than about 80% or notgreater than about 76% or not greater than about 73% or not greater thanabout 70% or not greater than about 68% of the width or not greater thanabout 56% of the width or not greater than about 48% of the width or notgreater than about 40% of the width.

Item 67. The fixed abrasive article of item 65, wherein the height (h)is at least about 400 microns or at least about 450 microns or at leastabout 475 microns or at least about 500 microns, and not greater thanabout 3 mm or not greater than about 2 mm or not greater than about 1.5mm or not greater than about 1 mm or not greater than about 800 microns.

Item 68. The fixed abrasive article of item 65, wherein the width is atleast about 600 microns or at least about 700 microns or at least about800 microns or at least about 900 microns, and not greater than about 4mm or not greater than about 3 mm or not greater than about 2.5 mm ornot greater than about 2 mm.

Item 69. The fixed abrasive article of item 65, wherein the bodycomprises a percent flashing of at least about 1%, such as at leastabout 2% or at least about 3% or at least about 5% or at least about 8%or at least about 10% or at least about 12% or at least about 15% or atleast about 18% or at least about 20%, and not greater than about 40% ornot greater than about 35% or not greater than about 30% or not greaterthan about 25% or not greater than about 20% or not greater than about18% or not greater than about 15% or not greater than about 12% or notgreater than about 10% or not greater than about 8% or not greater thanabout 6% or not greater than about 4%.

Item 70. The fixed abrasive article of item 65, wherein the bodycomprises a dishing value (d) of not greater than about 2 or not greaterthan about 1.9 or not greater than about 1.8 or not greater than about1.7 or not greater than about 1.6 or not greater than about 1.5 or notgreater than about 1.2, and at least about 0.9 or at least about 1.0.

Item 71. The fixed abrasive article of item 65, wherein the bodycomprises a primary aspect ratio of width:length of at least about 1:1and not greater than about 10:1.

Item 72. The fixed abrasive article of item 65, wherein the bodycomprises a secondary aspect ratio defined by a ratio of width:heightwithin a range between about 5:1 and about 1:1.

Item 73. The fixed abrasive article of item 65, wherein the bodycomprises a tertiary aspect ratio defined by a ratio of length:heightwithin a range between about 6:1 and about 1:1.

Item 74. The fixed abrasive article of item 65, wherein the bodycomprises a two-dimensional polygonal shape as viewed in a plane definedby a length and width, wherein the body comprises a shape selected fromthe group consisting of triangular, quadrilateral, rectangular,trapezoidal, pentagonal, hexagonal, heptagonal, octagonal, and acombination thereof, wherein the body comprises a two-dimensional shapeas viewed in a plane defined by a length and a width of the bodyselected from the group consisting of ellipsoids, Greek alphabetcharacters, Latin alphabet characters, Russian alphabet characters,complex polygonal shapes, irregular shapes, and a combination thereof.

Item 75. The fixed abrasive article of item 65, wherein the bodycomprises a two-dimensional triangular shape as viewed in a planedefined by a length and width.

Item 76. The fixed abrasive article of item 65, wherein the body isessentially free of a binder, wherein the body is essentially free of anorganic material.

Item 77. The fixed abrasive article of item 65, wherein the bodycomprises a polycrystalline material, wherein the polycrystallinematerial comprises grains, wherein the grains are selected from thegroup of materials consisting of nitrides, oxides, carbides, borides,oxynitrides, diamond, and a combination thereof, wherein the grainscomprise an oxide selected from the group of oxides consisting ofaluminum oxide, zirconium oxide, titanium oxide, yttrium oxide, chromiumoxide, strontium oxide, silicon oxide, and a combination thereof,wherein the grains comprise alumina, wherein the grains consistessentially of alumina.

Item 78. The fixed abrasive article of item 65, wherein the bodyconsists essentially of alumina.

Item 79. The fixed abrasive article of item 65, wherein the body isformed from a seeded sol gel.

Item 80. The fixed abrasive article of item 65, wherein the bodycomprises a polycrystalline material having an average grain size notgreater than about 1 micron.

Item 81. The fixed abrasive article of item 65, wherein the body is acomposite comprising at least about two different types of grains.

Item 82. The fixed abrasive article of item 65, wherein the bodycomprises an additive, wherein the additive comprises an oxide, whereinthe additive comprises a metal element, wherein the additive comprises arare-earth element.

Item 83. The fixed abrasive article of item 82, wherein the additivecomprises a dopant material, wherein the dopant material includes anelement selected from the group consisting of an alkali element, analkaline earth element, a rare earth element, a transition metalelement, and a combination thereof, wherein the dopant materialcomprises an element selected from the group consisting of hafnium,zirconium, niobium, tantalum, molybdenum, vanadium, lithium, sodium,potassium, magnesium, calcium, strontium, barium, scandium, yttrium,lanthanum, cesium, praseodymium, chromium, cobalt, iron, germanium,manganese, nickel, titanium, zinc, and a combination thereof.

Item 84. The fixed abrasive article of item 1, wherein the second typeof shaped abrasive particle comprises a body having a first majorsurface, a second major surface, and at least one side surface extendingbetween the first major surface and the second major surface.

Item 85. The fixed abrasive article of item 84, wherein the first majorsurface defines an area different than the second major surface, whereinthe first major surface defines an area greater than an area defined bythe second major surface, wherein the first major surface defines anarea less than an area defined by the second major surface.

Item 86. A fixed abrasive article comprising:

a blend of abrasive particles comprising:

-   a first type of shaped abrasive particle comprising a first height    (h1);-   a second type of shaped abrasive particle comprising a second height    (h2) less than the first height; and-   wherein the fixed abrasive article comprises a stainless steel    lifespan of at least about 11 in³.

Item 87. The fixed abrasive article of item 86, wherein the fixedabrasive article comprises a stainless steel lifespan of at least about11.5 in³ or at least about 12 in³, and wherein the fixed abrasivearticle comprises a stainless steel lifespan of not greater than about25 in³.

Item 88. The fixed abrasive article of item 86, further comprising aheight ratio (h2/h1) of not greater than about 0.98.

Item 89. The fixed abrasive article of item 88, wherein the height ratio(h2/h1) is at least about 0.05.

Item 90. The fixed abrasive article of item 86, further comprising aheight difference (h1−h2) of at least about 1 micron.

Item 91. The fixed abrasive article of item 90, wherein the heightdifference (h1−h2) is not greater than about 2 mm.

Item 92. The fixed abrasive article of item 86, wherein the first typeof shaped abrasive particle comprises a first length (l1), and thesecond type of shaped abrasive particle comprises a second length (l2),and further comprising a length ratio (l1/l2) of at least about 0.05.

Item 93. The fixed abrasive article of item 92, further comprising alength difference (L1−l2) of not greater than about 2 mm.

Item 94. The fixed abrasive article of item 86, wherein the first typeof shaped abrasive particle comprises a first width (w1), and the secondtype of shaped abrasive particle comprises a second width (w2), andfurther comprising a width ratio (w2/w1) of at least about 0.05.

Item 95. The fixed abrasive article of item 94, further comprising awidth difference (w1−w2) of not greater than about 2 mm.

Item 96. The fixed abrasive article of item 86, wherein the firstcontent is less than the second content.

Item 97. The fixed abrasive article of item 86, wherein the firstcontent is not greater than about 90% of a total content of the blend.

Item 98. The fixed abrasive article of item 86, wherein the firstcontent is at least about 1% of a total content of the blend.

Item 99. The fixed abrasive article of item 86, wherein the secondcontent is not greater than about 98% of a total content of the blend.

Item 100. The fixed abrasive article of item 86, wherein the secondcontent is at least about 1% of a total content of the blend.

Item 101. The fixed abrasive article of item 86, wherein the blend ofabrasive particles comprises a first content (C1) of the first type ofshaped abrasive particle, and a second content (C2) of the second typeof shaped abrasive particle, and further comprising a blend ratio(C1/C2) of not greater than about 10.

Item 102. The fixed abrasive article of item 86, wherein the blend ofabrasive particles includes a majority content of shaped abrasiveparticles, wherein the blend of abrasive particles consists essentiallyof the first type of shaped abrasive particle and the second type ofshaped abrasive particle.

Item 103. The fixed abrasive article of item 86, wherein the blendfurther comprises a third type of abrasive particle, wherein the thirdtype of abrasive particle comprises a shaped abrasive particle, whereinthe third type of abrasive particle comprises a diluent type of abrasiveparticle, wherein the diluent type of abrasive particle comprises anirregular shape.

Item 104. The fixed abrasive article of item 86, wherein the fixedabrasive article is selected from the group consisting of a bondedabrasive article, a coated abrasive article, and a combination thereof.

Item 105. The fixed abrasive article of item 86, wherein the fixedabrasive article comprises a substrate, wherein the substrate comprisesa backing, wherein the backing comprises a woven material, wherein thebacking comprises a non-woven material, wherein the backing comprises anorganic material, wherein the backing comprises a polymer, wherein thebacking comprises a material selected from the group consisting ofcloth, paper, film, fabric, fleeced fabric, vulcanized fiber, wovenmaterial, non-woven material, webbing, polymer, resin, phenolic resin,phenolic-latex resin, epoxy resin, polyester resin, urea-formaldehyderesin, polyester, polyurethane, polypropylene, polyimides, and acombination thereof.

Item 106. The fixed abrasive article of item 105, wherein the backingcomprises an additive selected from the group consisting of catalysts,coupling agents, curants, anti-static agents, suspending agents,anti-loading agents, lubricants, wetting agents, dyes, fillers,viscosity modifiers, dispersants, defoamers, and grinding agents.

Item 107. The fixed abrasive article of item 105, further comprising anadhesive layer overlying the backing, wherein the adhesive layercomprises a make coat, wherein the make coat overlies the backing,wherein the make coat is bonded directly to a portion of the backing,wherein the make coat comprises an organic material, wherein the makecoat comprises a polymeric material, wherein the make coat comprises amaterial selected from the group consisting of polyesters, epoxy resins,polyurethanes, polyamides, polyacrylates, polymethacrylates, poly vinylchlorides, polyethylene, polysiloxane, silicones, cellulose acetates,nitrocellulose, natural rubber, starch, shellac, and a combinationthereof.

Item 108. The fixed abrasive article of item 107, wherein the adhesivelayer comprises a size coat, wherein the size coat overlies a portion ofthe plurality of shaped abrasive particles, wherein the size coatoverlies a make coat, wherein the size coat is bonded directly to aportion of the plurality of shaped abrasive particles, wherein the sizecoat comprises an organic material, wherein the size coat comprises apolymeric material, wherein the size coat comprises a material selectedfrom the group consisting of polyesters, epoxy resins, polyurethanes,polyamides, polyacrylates, polymethacrylates, polyvinyl chlorides,polyethylene, polysiloxane, silicones, cellulose acetates,nitrocellulose, natural rubber, starch, shellac, and a combinationthereof.

Item 109. The fixed abrasive article of item 86, wherein the blend ofabrasive particles comprises a plurality of shaped abrasive particles,and wherein each shaped abrasive particle of the plurality of shapedabrasive particles is arranged in a controlled orientation relative to abacking, the controlled orientation including at least one of apredetermined rotational orientation, a predetermined lateralorientation, and a predetermined longitudinal orientation.

Item 110. The fixed abrasive article of item 86, wherein the first typeof shaped abrasive particle comprises a body having a length (l), awidth (w), and a height (hi), wherein the width>length, thelength>height, and the width>height.

Item 111. The fixed abrasive article of item 110, wherein the height (h)is at least about 20% of the width (w), and not greater than about 80%of the width.

Item 112. The fixed abrasive article of item 110, wherein the bodycomprises a percent flashing of at least about 1%.

Item 113. The fixed abrasive article of item 110, wherein the bodycomprises a dishing value (d) of not greater than about 2.

Item 114. The fixed abrasive article of item 110, wherein the bodycomprises a primary aspect ratio of width:length of at least about 1:1and not greater than about 10:1.

Item 115. The fixed abrasive article of item 110, wherein the bodycomprises a secondary aspect ratio defined by a ratio of width:heightwithin a range between about 5:1 and about 1:1.

Item 116. The fixed abrasive article of item 110, wherein the bodycomprises a tertiary aspect ratio defined by a ratio of length:heightwithin a range between about 6:1 and about 1:1.

Item 117. The fixed abrasive article of item 110, wherein the bodycomprises a two-dimensional polygonal shape as viewed in a plane definedby a length and width, wherein the body comprises a shape selected fromthe group consisting of triangular, quadrilateral, rectangular,trapezoidal, pentagonal, hexagonal, heptagonal, octagonal, and acombination thereof, wherein the body comprises a two-dimensional shapeas viewed in a plane defined by a length and a width of the bodyselected from the group consisting of ellipsoids, Greek alphabetcharacters, Latin alphabet characters, Russian alphabet characters,complex polygonal shapes, irregular shapes, and a combination thereof.

Item 118. The fixed abrasive article of item 110, wherein the body isessentially free of a binder, wherein the body is essentially free of anorganic material.

Item 119. The fixed abrasive article of item 110, wherein the bodycomprises a polycrystalline material, wherein the polycrystallinematerial comprises grains, wherein the grains are selected from thegroup of materials consisting of nitrides, oxides, carbides, borides,oxynitrides, diamond, and a combination thereof, wherein the grainscomprise an oxide selected from the group of oxides consisting ofaluminum oxide, zirconium oxide, titanium oxide, yttrium oxide, chromiumoxide, strontium oxide, silicon oxide, and a combination thereof,wherein the grains comprise alumina, wherein the grains consistessentially of alumina.

Item 120. The fixed abrasive article of item 110, wherein the bodycomprises an additive, wherein the additive comprises an oxide, whereinthe additive comprises a metal element, wherein the additive comprises arare-earth element.

Item 121. The fixed abrasive article of item 86, wherein the first typeof shaped abrasive particle comprises a first abrasive characteristicselected from the group consisting of two-dimensional shape, averageparticle size, particle color, hardness, friability, toughness, density,specific surface area, and a combination thereof.

Item 122. The fixed abrasive article of item 121, wherein the secondtype of shaped abrasive particle comprises a second abrasivecharacteristic selected from the group consisting of two-dimensionalshape, average particle size, particle color, hardness, friability,toughness, density, specific surface area, and a combination thereof.

Item 123. The fixed abrasive article of item 122, wherein at least onefirst abrasive characteristic and second abrasive characteristic areessentially the same compared to each other, wherein at least two firstabrasive characteristics and two second abrasive characteristics areessentially the same compared to each other.

Item 124. The fixed abrasive article of item 122, wherein at least onefirst abrasive characteristic and one second abrasive characteristic aredifferent compared to each other, wherein at least two first abrasivecharacteristics and two second abrasive characteristics are differentcompared to each other.

Item 125. The fixed abrasive article of item 110, wherein the secondtype of shaped abrasive particle comprises a body having a length (l), awidth (w), and a height (hi), wherein the width>length, thelength>height, and the width>height.

Item 126. The fixed abrasive article of item 125, wherein the height (h)is at least about 20% of the width (w), and not greater than about 80%of the width.

Item 127. The fixed abrasive article of item 125, wherein the height (h)is at least about 400 microns.

Item 128. The fixed abrasive article of item 125, wherein the width isat least about 600 microns.

Item 129. The fixed abrasive article of item 125, wherein the bodycomprises a percent flashing of at least about 1%.

Item 130. The fixed abrasive article of item 125, wherein the bodycomprises a dishing value (d) of not greater than about 2.

Item 131. The fixed abrasive article of item 125, wherein the bodycomprises a primary aspect ratio of width:length of at least about 1:1and not greater than about 10:1.

Item 132. The fixed abrasive article of item 125, wherein the bodycomprises a secondary aspect ratio defined by a ratio of width:heightwithin a range between about 5:1 and about 1:1.

Item 133. The fixed abrasive article of item 125, wherein the bodycomprises a tertiary aspect ratio defined by a ratio of length:heightwithin a range between about 6:1 and about 1:1.

Item 134. The fixed abrasive article of item 125, wherein the bodycomprises a two-dimensional polygonal shape as viewed in a plane definedby a length and width, wherein the body comprises a shape selected fromthe group consisting of triangular, quadrilateral, rectangular,trapezoidal, pentagonal, hexagonal, heptagonal, octagonal, and acombination thereof, wherein the body comprises a two-dimensional shapeas viewed in a plane defined by a length and a width of the bodyselected from the group consisting of ellipsoids, Greek alphabetcharacters, Latin alphabet characters, Russian alphabet characters,complex polygonal shapes, irregular shapes, and a combination thereof.

Item 135. The fixed abrasive article of item 125, wherein the bodycomprises a two-dimensional triangular shape as viewed in a planedefined by a length and width.

Item 136. The fixed abrasive article of item 125, wherein the body isessentially free of a binder, wherein the body is essentially free of anorganic material.

Item 137. The fixed abrasive article of item 125, wherein the bodycomprises a polycrystalline material, wherein the polycrystallinematerial comprises grains, wherein the grains are selected from thegroup of materials consisting of nitrides, oxides, carbides, borides,oxynitrides, diamond, and a combination thereof, wherein the grainscomprise an oxide selected from the group of oxides consisting ofaluminum oxide, zirconium oxide, titanium oxide, yttrium oxide, chromiumoxide, strontium oxide, silicon oxide, and a combination thereof,wherein the grains comprise alumina, wherein the grains consistessentially of alumina.

Item 138. The fixed abrasive article of item 125, wherein the body is acomposite comprising at least about 2 different types of abrasivegrains.

Item 139. The fixed abrasive article of item 125, wherein the bodycomprises an additive, wherein the additive comprises an oxide, whereinthe additive comprises a metal element, wherein the additive comprises arare-earth element.

Item 140. The fixed abrasive article of item 125, wherein the additivecomprises a dopant material, wherein the dopant material includes anelement selected from the group consisting of an alkali element, analkaline earth element, a rare earth element, a transition metalelement, and a combination thereof, wherein the dopant materialcomprises an element selected from the group consisting of hafnium,zirconium, niobium, tantalum, molybdenum, vanadium, lithium, sodium,potassium, magnesium, calcium, strontium, barium, scandium, yttrium,lanthanum, cesium, praseodymium, chromium, cobalt, iron, germanium,manganese, nickel, titanium, zinc, and a combination thereof.

Item 141. A method of removing material from a workpiece using anabrasive article including a blend of abrasive particles comprising:

-   a first type of shaped abrasive particle comprising a first height    (h1);-   a second type of shaped abrasive particle comprising a second height    (h2) less than the first height.

Item 142. The method of item 141, wherein the workpiece comprises amaterial selected from the group consisting of an organic material, aninorganic material, and a combination thereof, wherein the workpiececomprises a metal, wherein the workpiece comprises a metal alloy.

Item 143. The method of item 141, wherein the fixed abrasive articlecomprises a stainless steel lifespan of at least about 11 in³.

Item 144. The method of item 141, further comprising a height ratio(h2/h1) of not greater than about 0.98.

Item 145. The method of item 144, wherein the height ratio (h2/h1) is atleast about 0.05.

Item 146. The method of item 141, further comprising a height difference(h1−h2) of at least about 1 micron.

Item 147. The method of item 146, wherein the height difference (h1−h2)is not greater than about 2 mm.

Item 148. The method of item 141, wherein the first type of shapedabrasive particle comprises a first length (l1), and the second type ofshaped abrasive particle comprises a second length (l2), and furthercomprising a length ratio (l1/l2) of at least about 0.05.

Item 149. The method of item 148, further comprising a length difference(L1−l2) of not greater than about 2 mm.

Item 150. The method of item 141, wherein the first type of shapedabrasive particle comprises a first width (w1), and the second type ofshaped abrasive particle comprises a second width (w2), and furthercomprising a width ratio (w2/w1) of at least about 0.05.

Item 151. The method of item 150, further comprising a width difference(w1−w2) of not greater than about 2 mm.

Item 152. The method of item 141, wherein the blend of abrasiveparticles comprises a first content (C1) of the first type of shapedabrasive particle, and a second content (C2) of the second type ofshaped abrasive particle, and further comprising a blend ratio (C1/C2)of not greater than about 10.

Item 153. The method of item 141, wherein the blend of abrasiveparticles includes a majority content of shaped abrasive particles,wherein the blend of abrasive particles consists essentially of thefirst type of shaped abrasive particle and the second type of shapedabrasive particle.

Item 154. The method of item 141, wherein the blend further comprises athird type of abrasive particle, wherein the third type of abrasiveparticle comprises a shaped abrasive particle, wherein the third type ofabrasive particle comprises a diluent type of abrasive particle, whereinthe diluent type of abrasive particle comprises an irregular shape.

Item 155. The method of item 141, wherein the fixed abrasive article isselected from the group consisting of a bonded abrasive article, acoated abrasive article, and a combination thereof.

Item 156. The method of item 141, wherein the fixed abrasive articlecomprises a substrate, wherein the substrate comprises a backing,wherein the backing comprises a woven material, wherein the backingcomprises a non-woven material, wherein the backing comprises an organicmaterial, wherein the backing comprises a polymer, wherein the backingcomprises a material selected from the group consisting of cloth, paper,film, fabric, fleeced fabric, vulcanized fiber, woven material,non-woven material, webbing, polymer, resin, phenolic resin,phenolic-latex resin, epoxy resin, polyester resin, urea-formaldehyderesin, polyester, polyurethane, polypropylene, polyimides, and acombination thereof.

Item 157. The method of item 156, wherein the backing comprises anadditive selected from the group consisting of catalysts, couplingagents, curants, anti-static agents, suspending agents, anti-loadingagents, lubricants, wetting agents, dyes, fillers, viscosity modifiers,dispersants, defoamers, and grinding agents.

Item 158. The method of item 157, wherein further comprising an adhesivelayer overlying the backing, wherein the adhesive layer comprises a makecoat, wherein the make coat overlies the backing, wherein the make coatis bonded directly to a portion of the backing, wherein the make coatcomprises an organic material, wherein the make coat comprises apolymeric material, wherein the make coat comprises a material selectedfrom the group consisting of polyesters, epoxy resins, polyurethanes,polyamides, polyacrylates, polymethacrylates, poly vinyl chlorides,polyethylene, polysiloxane, silicones, cellulose acetates,nitrocellulose, natural rubber, starch, shellac, and a combinationthereof.

Item 159. The method of item 158, wherein the adhesive layer comprises asize coat, wherein the size coat overlies a portion of the plurality ofshaped abrasive particles, wherein the size coat overlies a make coat,wherein the size coat is bonded directly to a portion of the pluralityof shaped abrasive particles, wherein the size coat comprises an organicmaterial, wherein the size coat comprises a polymeric material, whereinthe size coat comprises a material selected from the group consisting ofpolyesters, epoxy resins, polyurethanes, polyamides, polyacrylates,polymethacrylates, polyvinyl chlorides, polyethylene, polysiloxane,silicones, cellulose acetates, nitrocellulose, natural rubber, starch,shellac, and a combination thereof.

Item 160. The method of item 141, wherein the blend of abrasiveparticles comprises a plurality of shaped abrasive particles, andwherein each shaped abrasive particle of the plurality of shapedabrasive particles is arranged in a controlled orientation relative to abacking, the controlled orientation including at least one of apredetermined rotational orientation, a predetermined lateralorientation, and a predetermined longitudinal orientation.

EXAMPLES Example 1

Five samples were used to conduct a comparative grinding operation. Eachof the five samples used essentially the same structure, includingbacking and adhesive layers; however, the samples differed in the typeof abrasive particles. A first sample, Sample S1, represents a coatedabrasive, including a blend of shaped abrasive particles according toembodiments described herein. Sample S1 includes a plurality of a firsttype of shaped abrasive particles having a median internal height ofapproximately 500 microns. The blend further includes a plurality of asecond type of shaped abrasive particles having a median internal heightof approximately 400 microns. The blend has a ratio (C1/C2) ofapproximately 2.3. Approximately 80% of the shaped abrasive particles ofthe blend are positioned in a predetermined side orientation on thebacking and have a normalized weight of shaped abrasive particles of 40lbs./ream.

A second sample, Sample S2, represents a coated abrasive, including ablend of shaped abrasive particles according to embodiments describedherein. Sample S1 includes a plurality of a first type of shapedabrasive particles having a median internal height of approximately 500microns. The blend further includes a plurality of a second type ofshaped abrasive particles having a median internal height ofapproximately 400 microns. The blend has a ratio (C1/C2) ofapproximately 1. Approximately 80% of the shaped abrasive particles ofthe blend are positioned in a predetermined side orientation on thebacking and have a normalized weight of shaped abrasive particles of 40lbs./ream.

A third sample, Sample S3, represents a coated abrasive, including ablend of shaped abrasive particles according to embodiments describedherein. Sample S1 includes a plurality of a first type of shapedabrasive particles having a median internal height of approximately 500microns. The blend further includes a plurality of a second type ofshaped abrasive particles having a median internal height ofapproximately 400 microns. The blend has a ratio (C1/C2) ofapproximately 0.43. Approximately 80% of the shaped abrasive particlesof the blend are positioned in a predetermined side orientation on thebacking and have a normalized weight of shaped abrasive particles of 40lbs./ream.

A fourth sample, Sample CS4 represents a conventional coated abrasivearticle including a single type of shaped abrasive particle having amedian internal height of approximately 400 microns. Approximately 80%of these shaped abrasive particles are positioned in a predeterminedside orientation on the backing and have a normalized weight of shapedabrasive particles of 40 lbs./ream.

A fifth sample, Sample CS5, represents a conventional coated abrasivearticle, including a single type of shaped abrasive particle having amedian internal height of approximately 500 microns. Approximately 80%of these shaped abrasive particles are positioned in a predeterminedside orientation on the backing and have a normalized weight of shapedabrasive particles of 40 lbs./ream.

The samples were tested in an automated grinding system according to theconditions provided in Table 1 below.

TABLE 1 Test platform: Okuma Screening Test Test conditions: Dry,Straight Plunge Constant MRR′ = 4 inch³/min/inch Belt speed = Vs = 7500sfpm (38 m/s) Work material: 304L ss Hardness: 104 HRB Size: 0.5″ × 0.5″× 6 inches Contact width = 0.5″ inch Measurements: Power, GrindingForces, MRR′ and SGE

FIG. 11 includes a plot of specific grinding energy versus cumulativematerial removed for each of the samples. As clearly illustrated, thelife of Sample CS5 was significantly less than Samples S2 and S3. Quiteremarkably, and unexpectedly, and despite Samples S2-S3 having a blendof a first type of shaped abrasive particle and a second type of shapedabrasive particle, which may be expected to have a cumulative materialremoval rate that is between Samples CS4 and CS5, Samples S2 and S3 hada life that was equivalent to CS4 and greater than CS5. Moreover, eachof the Samples S1-S3 had an initial specific grinding energy between 0to 5 cubic inches of material removed that was lower than thecomparative samples CS4 and CS5 in the same initial stages. Moreover,and equally unexpected, Sample S3 has a lower specific grinding energyfor the majority of the test as compared to either Sample CS1 or SampleCS2.

The present application represents a departure from the state of theart. The coated abrasive articles of the embodiments herein include aparticular combination of features distinct from other conventionallyavailable abrasive articles, including, but not limited to,incorporation of a blend including a first type of shaped abrasiveparticle and a second type of shaped abrasive particle. Notably, thefirst type and second type of shaped abrasive particles can have aparticular combination of features, including, but not limited to, adifference in height with respect to each other. Moreover, each of theshaped abrasive particles can have particular features, such as aspectratio, composition, additives, two-dimensional shape, three-dimensionalshape, intern height, difference in height profile, flashing percentage,dishing, and the like. Moreover, the blend may utilize a combination ofcertain features including, but not limited to, height ratio, heightdifference, length ratio, length difference, width ratio, widthdifference, relative contents of the first and second types of shapedabrasive particles, and the like. Moreover, while not completelyunderstood and without wishing to be tied to a particular theory, it isthought that one or a combination of these features of the embodimentsdescribed herein facilitate the remarkable and unexpected performance ofthese coated abrasive articles. [00326]Certain features, for clarity,described herein in the context of separate embodiments, may also beprovided in combination in a single embodiment. Conversely, variousfeatures that are, for brevity, described in the context of a singleembodiment, may also be provided separately or in any subcombination.Further, reference to values stated in ranges includes each and everyvalue within that range.

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any feature(s) that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature of any or all the claims.

The specification and illustrations of the embodiments described hereinare intended to provide a general understanding of the structure of thevarious embodiments. The specification and illustrations are notintended to serve as an exhaustive and comprehensive description of allof the elements and features of apparatus and systems that use thestructures or methods described herein. Separate embodiments may also beprovided in combination in a single embodiment, and conversely, variousfeatures that are, for brevity, described in the context of a singleembodiment, may also be provided separately or in any subcombination.Further, reference to values stated in ranges includes each and everyvalue within that range. Many other embodiments may be apparent toskilled artisans only after reading this specification. Otherembodiments may be used and derived from the disclosure, such that astructural substitution, logical substitution, or another change may bemade without departing from the scope of the disclosure. Accordingly,the disclosure is to be regarded as illustrative rather thanrestrictive.

The following description in combination with the figures is provided toassist in understanding the teachings disclosed herein. The followingdiscussion will focus on specific implementations and embodiments of theteachings. This focus is provided to assist in describing the teachingsand should not be interpreted as a limitation on the scope orapplicability of the teachings. However, other teachings can certainlybe used in this application.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a method,article, or apparatus that comprises a list of features is notnecessarily limited only to those features but may include otherfeatures not expressly listed or inherent to such method, article, orapparatus. Further, unless expressly stated to the contrary, “or” refersto an inclusive-or and not to an exclusive-or. For example, a conditionA or B is satisfied by any one of the following: A is true (or present)and B is false (or not present), A is false (or not present) and B istrue (or present), and both A and B are true (or present).

Also, the use of “a” or “an” is employed to describe elements andcomponents described herein. This is done merely for convenience and togive a general sense of the scope of the invention. This descriptionshould be read to include one or at least one and the singular alsoincludes the plural, or vice versa, unless it is clear that it is meantotherwise. For example, when a single item is described herein, morethan one item may be used in place of a single item. Similarly, wheremore than one item is described herein, a single item may be substitutedfor that more than one item.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. The materials, methods, andexamples are illustrative only and not intended to be limiting. To theextent not described herein, many details regarding specific materialsand processing acts are conventional and may be found in reference booksand other sources within the structural arts and correspondingmanufacturing arts.

The above-disclosed subject matter is to be considered illustrative, andnot restrictive, and the appended claims are intended to cover all suchmodifications, enhancements, and other embodiments, which fall withinthe true scope of the present invention. Thus, to the maximum extentallowed by law, the scope of the present invention is to be determinedby the broadest permissible interpretation of the following claims andtheir equivalents, and shall not be restricted or limited by theforegoing detailed description.

The Abstract of the Disclosure is provided to comply with Patent Law andis submitted with the understanding that it will not be used tointerpret or limit the scope or meaning of the claims. In addition, inthe foregoing Detailed Description of the Drawings, various features maybe grouped together or described in a single embodiment for the purposeof streamlining the disclosure. This disclosure is not to be interpretedas reflecting an intention that the claimed embodiments require morefeatures than are expressly recited in each claim. Rather, as thefollowing claims reflect, inventive subject matter may be directed toless than all features of any of the disclosed embodiments. Thus, thefollowing claims are incorporated into the Detailed Description of theDrawings, with each claim standing on its own as defining separatelyclaimed subject matter.

What is claimed is:
 1. A coated abrasive article comprising: a blend ofabrasive particles comprising: a first content (C1) of a first type ofshaped abrasive particle comprising a first height (h1); a secondcontent (C2) of a second type of shaped abrasive particle comprising asecond height (h2) less than the first height, and wherein the firstcontent is at least about 1% and not greater than about 70% of the totalcontent of the blend, and wherein the second content at least about 1%and not greater than about 98% of the total content of the blend, andwherein at least a portion of the abrasive particles are in an open coatconfiguration, and wherein the coated abrasive article has an open-coatcoating density of shaped abrasive particles of not greater than about70 particles/cm².
 2. The coated abrasive article of claim 1, wherein thecoated abrasive article has an open-coat coating density of shapedabrasive particles of at least 5 particles/cm².
 3. The coated abrasivearticle of claim 1, further comprising an additive.
 4. The coatedabrasive article of claim 3, wherein the additive is a grinding agent.5. The coated abrasive article of claim 1, wherein the coated abrasivearticle has an open-coat coating density of the first type of shapedabrasive particles of at least 5 particles/cm².
 6. The coated abrasivearticle of claim 1, wherein the coated abrasive article has an open-coatcoating density of a first type of shaped abrasive particles of notgreater than 70 particles/cm².
 7. The coated abrasive article of claim1, wherein the coated abrasive article has an open-coat coating densityof the second type of shaped abrasive particles of at least 5particles/cm².
 8. The coated abrasive article of claim 1, wherein thecoated abrasive article has an open-coat coating density of a secondtype of shaped abrasive particles of not greater than 70 particles/cm².9. The coated abrasive article of claim 1, wherein the percentagecoating of the abrasive particles relative to the total area of theabrasive surface can be not greater than 50%.
 10. The coated abrasivearticle of claim 1, wherein the blend of abrasive particles has a blendratio (C1/C2) of at least about 0.1 and not greater than about 1.0. 11.The coated abrasive article of claim 1, wherein the abrasive particleshave a height ratio (h2/h1) of at least about 0.05 and not greater thanabout 0.98.
 12. The coated abrasive article of claim 1, wherein theabrasive particles have a height difference (h1−h2) of at least about 1micron and not greater than about 2 mm.
 13. The coated abrasive articleof claim 1, wherein a majority of the first type of abrasive particlesare coupled to the backing in a side orientation.
 14. The coatedabrasive article of claim 1, wherein a majority of the second type ofabrasive particles are coupled to the backing in a side orientation. 15.The coated abrasive article of claim 1, wherein each shaped abrasiveparticle of the first type of shaped abrasive particles comprises a bodyhaving a height and a width, and wherein the body comprises atwo-dimensional shape in the plane of a length and the width selectedfrom the group consisting of triangular, quadrilateral, rectangular,trapezoidal, pentagonal, hexagonal, heptagonal, octagonal, and acombination thereof.
 16. The coated abrasive article of claim 15,wherein the body comprises a two-dimensional triangular shape as viewedin a plane defined by a length and width.
 17. The coated abrasivearticle of claim 15, wherein the body is essentially free of a binder.18. The coated abrasive article of claim 15, wherein the body has anupper surface with an upper surface area, and a lower surface with alower surface area, wherein the upper surface area is different than thelower surface area.
 19. The coated abrasive article of claim 15, whereinthe body comprises alumina.
 20. The coated abrasive article of claim 1,wherein the blend of abrasive particles further comprises a third typeof abrasive particles, wherein the third type of abrasive particlescomprises diluent abrasive particles.